NHTSA Complaint #11631525 — 2021 FORD BRONCO SPORT

The car caught fire the morning of Dec 11, 2024 while the vehicle's owner was driving their children to school. There are photos and a fire report is being generated. The vehicle's owner and her children could have been killed. Early indications are that the fire was caused by the same faulty engine/exhaust system defect that the owner has been complaining to Ford about for years. It is assumed the fire report will confirm that. For the past two or more years the vehicle has been emitting exhaust fumes into the passenger compartment of the vehicle while driving. This has caused the vehicle's owner and her children to get sick and forced them to drive the vehicle with the windows down at all times even in cold weather. Ford's dealers have confirmed the problem several times, but either could not or refused to fix it. A summary of the vehicle's service history is included below: 35,662 miles Customer states inside of vehicle smells like exhaust. 37,431 miles Inside of vehicle smells like exhaust. 39,856 miles inside of vehicle smells like exhaust. confirmed customers concern found cat warped at mating surface to turbo replacement required. 46,832 miles Fumes getting inside the Cab, seems to be blowing in from vents. Misdiagnosed as blower motor electrical smell and missed broken catalyst. 47,300 miles Customer had car towed into shop stating car was shaking and smelled flumes inside the car. Verified concern that exhaust smell was present in car and loud noise was coming from engine, found catalytic converter had broken at flange to turbo causing exhaust leak. Recommend new catalytic converter, removed and replaced catalytic converter. Low pressure fuel injectors are leaking. Verified customer concern, found fuel seeping out of all 3 low side injectors, recommend injector replacement, remove and replaced all 3 low side fuel injectors, found no other leak at this time. Found injectors were leaking fuel. 47,829 miles Check engine light. Remove and replace purge valve.