NHTSA Complaint #11684571 — 2021 FORD BRONCO SPORT

I am reporting a serious and recurring issue with the catalytic converter on my 2021 Ford Bronco Sport (1.5L EcoBoost), which has resulted in reduced efficiency and partial blockage, causing exhaust gases to enter the cabin and triggering engine code P0171. My safety and the safety of others have been compromised because exhaust fumes, including carbon monoxide, have entered the cabin, which is particularly dangerous as I am currently pregnant. In addition, the engine experiences RPM fluctuations and revs up on its own, sometimes hesitating during acceleration, creating a risk of loss of control or accidents, and reduced engine efficiency contributes to unpredictable vehicle behavior. The problem has been confirmed by a dealership, which diagnosed the catalytic converter inefficiency and provided a $2,000 replacement quote. This issue has been widely reported among other 2021 Bronco Sport owners, indicating a recurring problem. The vehicle has been inspected by the dealership, which ran diagnostics and verified the codes. Prior to the failure, the Check Engine Light illuminated, and I experienced exhaust fumes in the cabin, unusual odors, reduced engine performance, and RPM surges with hesitation during acceleration, first appearing around 80,000. This defect poses not only a serious safety hazard, but also environmental concerns, as the failing catalytic converter increases emissions of harmful gases, including carbon monoxide, hydrocarbons, and nitrogen oxides, contributing to air pollution and greenhouse gas emissions. I respectfully request that this issue be formally investigated by Ford and NHTSA for a possible recall, that consideration be given to goodwill or warranty coverage for affected vehicles, that guidance be provided for the safe operation of vehicles exhibiting this defect, particularly for pregnant passengers or others at risk, and that the environmental impact of this defect be considered during the investigation.