Mar 26, 2025
I’m writing this to highlight ongoing, severe issues with my 2021 Ford Bronco Sport that have caused considerable frustration and concern for my safety. These problems have persisted despite my best efforts to address them, and I want to make sure that others are aware of the serious nature of the defects involved.
In November 2023, at 60,600 miles (just outside of warranty), I had to replace the RDU (Rear Drive Unit), and this was only the beginning of the issues. Since then, I’ve been dealing with a series of dangerous malfunctions that Ford has failed to address properly.
It all started with a 4WD system fault error and a "shift solenoid stuck open" warning. Ford's service department informed me that they would not replace the valve body or solenoid, and instead, they suggested a full transmission replacement. The service manager’s response was, “We won’t replace these parts; you need a new transmission.” As someone who is not a trained technician, but has a friend who worked as a Ford service tech, this didn’t make sense to me. Why not address the known issues first, rather than jumping straight to a full transmission replacement?
After doing my own research, I decided to replace the valve body myself, using my tech friend’s computer software to flash the new part. The solenoid code cleared, but the issues didn’t stop there.
The most alarming part of the story is the ongoing failure of the 4WD system. I had to replace a faulty drive shaft speed sensor, and that’s when I discovered that Ford had failed to plug it back in when they replaced the RDU—despite charging me $3500 for the repair. Once I plugged the sensor in correctly, the code disappeared.
However, despite this fix, I am still dealing with severe symptoms that I can no longer ignore:
This problem is not isolated to my vehicle—it’s a known issue that is now circulating on the web. Consumers across the country are dealing with the same faults. These are not minor issues; they are safety concerns that Ford needs to address immediately. The car is essentially unusable in its current state, and I feel the company is failing to protect consumers by not acknowledging or taking action on these widespread defects.
I’ve reported this issue to NHTSA and have been advised to also file a complaint with the Federal Trade Commission. I strongly urge anyone else experiencing similar problems with their Bronco Sport (or full-size Bronco) to take immediate action. We cannot let this slide.
Has anyone else dealt with these serious transmission and 4WD system issues in their Bronco? This needs to be addressed on a larger scale. I’m sharing this in the hopes that it brings more awareness to these critical, unresolved safety concerns.
In November 2023, at 60,600 miles (just outside of warranty), I had to replace the RDU (Rear Drive Unit), and this was only the beginning of the issues. Since then, I’ve been dealing with a series of dangerous malfunctions that Ford has failed to address properly.
It all started with a 4WD system fault error and a "shift solenoid stuck open" warning. Ford's service department informed me that they would not replace the valve body or solenoid, and instead, they suggested a full transmission replacement. The service manager’s response was, “We won’t replace these parts; you need a new transmission.” As someone who is not a trained technician, but has a friend who worked as a Ford service tech, this didn’t make sense to me. Why not address the known issues first, rather than jumping straight to a full transmission replacement?
After doing my own research, I decided to replace the valve body myself, using my tech friend’s computer software to flash the new part. The solenoid code cleared, but the issues didn’t stop there.
The most alarming part of the story is the ongoing failure of the 4WD system. I had to replace a faulty drive shaft speed sensor, and that’s when I discovered that Ford had failed to plug it back in when they replaced the RDU—despite charging me $3500 for the repair. Once I plugged the sensor in correctly, the code disappeared.
However, despite this fix, I am still dealing with severe symptoms that I can no longer ignore:
- Unpredictable shifting behavior: When I put the car in neutral and try to drive forward, it often drives forward when I put it in reverse. When in Drive, the car sometimes refuses to move. I have to engage Low gear, then shift back into Drive, after which the gear selections (except Park) may work.
- New Park gear issue: I’ve now begun getting an error where the vehicle doesn’t engage Park properly, and I’m advised to apply the parking brake before exiting. This new issue is highly concerning and should never happen in a modern vehicle.
- Wrench warning & ignition issues: The most serious problem I’m facing is that when I go to put the car in Park after starting it, it will often not start again unless I attempt to restart it several times. Once I get the car to restart (usually on the 3rd or 4th try), the wrench warning disappears, and I can turn the car off and remove the key. If I don't go through this restart process, the key stays stuck in the ignition, and I cannot remove it. This is extremely frustrating and concerning for safety.
This problem is not isolated to my vehicle—it’s a known issue that is now circulating on the web. Consumers across the country are dealing with the same faults. These are not minor issues; they are safety concerns that Ford needs to address immediately. The car is essentially unusable in its current state, and I feel the company is failing to protect consumers by not acknowledging or taking action on these widespread defects.
I’ve reported this issue to NHTSA and have been advised to also file a complaint with the Federal Trade Commission. I strongly urge anyone else experiencing similar problems with their Bronco Sport (or full-size Bronco) to take immediate action. We cannot let this slide.
Has anyone else dealt with these serious transmission and 4WD system issues in their Bronco? This needs to be addressed on a larger scale. I’m sharing this in the hopes that it brings more awareness to these critical, unresolved safety concerns.
James77