As Ford Authority reported in July 2024, the National Highway Traffic Safety Administration (NHTSA) launched an investigation into the 2021 Ford Bronco after its Office of Defects Investigation (ODI) received six complaints from owners pertaining to fuel pump failures. That problem was estimated to potentially impact 45,597 different Ford Bronco SUVs from the first model year of the sixth-generation, but now, that investigation has officially been closed.
Ultimately, this investigation found that several other Blue Oval models could lose fuel pressure and flow from the fuel delivery module – which consists of the low-pressure fuel pump, jet pump, reservoir, and various other parts, all due to a low-pressure fuel pump failure. It determined that the root cause of this issue pertains to reduced internal clearance in the fuel pump, increasing friction and sensitivity to vapor lock, along with contamination inside the jet pump that can result in fuel blockage as well.
This past July, Ford issued a recall for around 850,000 total 2021-2023 Ford Bronco, Ford Explorer, Lincoln Aviator, Ford Super Duty F-250, F-350, F-450, F-550, 2021-2022 Lincoln Navigator, Ford Mustang, Ford F-150, and 2022 Ford Expedition models due to this very same issue with the low-pressure fuel pump. Though a remedy isn’t yet ready, the automaker noted that it has discovered the problem stems from a fuel pump design that has since undergone some changes by the supplier that makes it, effectively resolving the issue.
Ford stated that the supplier originally modified its jet pump manufacturing process for the low-pressure fuel pumps, producing the unit’s chambers with a lower-than-specified internal clearance. In July 2022, the supplier implemented corrective actions to the manufacturing process by adding two additional vacuum pumps to reduce contamination during the production of the jet pump. As such, ODI is closing its investigation into the matter, but as always, it reserves the right to reopen the query if this issue isn’t resolved in a satisfactory manner.
A little good news in a rather expensive world.
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