Vehicle was taken to Bowen [XXX] ([XXX]) for a transmission rebuild under RO #XXX, following repeated transmission failures. Dealer performed a complete teardown and rebuild of the transmission (replacing clutch components, seals, gaskets, fluid, reprogramming solenoids), and the repair order states the vehicle was road tested after repair with no DTCs present and "operating as designed." Vehicle was picked up on XXX at 11:20 AM. Approximately 24 hours later, on XXX at approximately 3:49 PM, while the vehicle was stationary, the instrument cluster displayed a "Shift System Fault, Service Required" warning, and the vehicle would not shift into any gear other than Park. The vehicle had to be towed by Ford Roadside Assistance back to Bowen [XXX] (tow reference #XXX). This is part of a pattern of recurring transmission-related failures on this vehicle since purchase, resulting in the vehicle being out of service for a substantial period across multiple repair attempts. A shift system fault rendering the vehicle undriveable in park-only mode, occurring within 24 hours of a certified "repair complete" transmission rebuild, raises serious concerns about the reliability and safety of the transmission system in this vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Source: NHTSA complaint ODI #11764593 · view all complaints for this vehicle at nhtsa.gov

The contact owns a 2025 Ford Bronco Sport. The contact stated that while driving at approximately 20 MPH, the instrument cluster turned blank. The vehicle was steered to the side the side of the road and was restarted; however, the failure persisted. The vehicle was taken to an unknown dealer, where it was diagnosed that the instrument cluster needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 80.

Source: NHTSA complaint ODI #11654043 · view all complaints for this vehicle at nhtsa.gov

Both front lower control arm ball joints on my 2025 Bronco Sport failed prematurely at approximately 13,000 miles. Upon removal, both ball studs showed heavy corrosion and clear evidence of water intrusion past the factory boot seals. One boot's upper metal retainer was visibly deformed, allowing water into the joint. This level of corrosion should not exist on a vehicle this new and indicates a defective component or seal, not normal wear. I have retained both failed parts and have photographs documenting the condition. This is the same component covered under Ford's active do-not-drive safety recall 26S36 (NHTSA campaign 26V-340) for front lower control arm ball joint defects on 2021–2026 Bronco Sport vehicles. My VIN is not included in that campaign, but I experienced failure of the identical safety-critical component. I am reporting this so NHTSA is aware the defect may extend beyond the current recall population. When I brought the vehicle to my local Ford dealer and requested inspection under the new vehicle warranty, the service department refused to inspect the vehicle at all, citing a 1.5-inch aftermarket leveling kit. No inspection was performed and no determination was made that the modification caused or contributed to the failure. A leveling kit does not cause water intrusion past a factory boot seal. Because the dealer refused service on a safety-critical component, I replaced both ball joints at my own expense to keep the vehicle safe to drive. I have opened a case with Ford Customer Relationship Center (case CXH-09202228-R9R8V5). No crash or injury occurred, but ball joint separation causes loss of steering control, and I believe this failure mode warrants investigation of vehicles outside the current recall scope.

Source: NHTSA complaint ODI #11761381 · view all complaints for this vehicle at nhtsa.gov

The contact owned a 2025 Ford Bronco Sport. While the contact’s brother-in-law was driving approximately 55 MPH, the vehicle crashed into the rear of another vehicle, causing the vehicle to flip over and slide between 50 and 75 yards. During the crash, the Forward Collision Avoidance system failed to activate, and the front driver’s side air bags did not deploy. The driver was later taken to the hospital and treated for a concussion and arm and leg abrasions. A Police report was filed at the scene, and the vehicle was towed away and later deemed a total loss by the insurance company. The cause of the failure was not yet determined. The manufacturer and local dealer were not notified of the failure. The failure mileage was 20,500.

Source: NHTSA complaint ODI #11753571 · view all complaints for this vehicle at nhtsa.gov

My daughter was driving the vehicle. She left home, drove 2 miles to drop someone off, and returned home on a 2 lane road with a 30mph speed limit. Approximately half way home, while travelling approximately 30-35mph, the hood on the vehicle flew open. It shattered the windshield, bent the hood, and because the hood flew so far back, the top of both front side panels were bent back. The last time the hood had been opened was long before to have the oil changed. There were no warning lights about the hood, and the vehicle had been used quite a bit that day, and at speeds higher than it was travelling when the hood flew open, before the incident occured. We are concerned about latch failure.

Source: NHTSA complaint ODI #11751483 · view all complaints for this vehicle at nhtsa.gov

I am submitting a safety concern regarding the 2025 Ford Bronco Off‑Road. Within 24 hours of purchasing my vehicle, a front sensor failed. The dealership reported that the sensor was damaged by a small rock while driving on normal paved roads. The repair cost is approximately $1,500 and is not covered under warranty. My concern is that a critical sensor—part of the vehicle’s safety and driver‑assistance systems—can be disabled by minor road debris. If this component is so vulnerable that everyday driving conditions can render it inoperable, it may pose a broader safety issue for consumers. This appears to be a design vulnerability that could affect many owners, potentially compromising safety features and creating significant financial burden. I am requesting that NHTSA review whether the placement and durability of this sensor meet reasonable safety expectations. Thank you for your time. Sincerely, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Source: NHTSA complaint ODI #11719300 · view all complaints for this vehicle at nhtsa.gov