More than 565,000 Ford Broncos face recall due to the risk of a fire, the automaker and the National Highway Traffic Safety Administration announced. The problem is due to potential wiring harness damage. The move brings to more than 50 the number of Ford recalls so far this year, reports Headlight.News.
The recall covers 2021-2026 Broncos and Bronco Raptors.
A wiring harness issue could create a short circuit leading to a fire in certain Ford Bronco models, a concern leading to a new recall covering more than 500,000 of the popular SUVs.
The automaker has begun notifying owners to be aware of the problem, though it cautioned that it has not yet got a fix in place.
The recall is Ford’s fourth this month, and brings to more than 50 the total number of service actions the automaker has had to take this year, covering over 10 million vehicles. Ford set an all-time industry recall record in 2025.
What’s behind the recall?
The Bronco Sport has is not covered by this recall.
According tp the automaker and the National Highway Traffic Safety Administration some Bronco models may have experienced wiring harness damage. If so, that could lead to a short circuit in the engine compartment. In turn, that could lead to a fire.
In a notice released this week, Ford said a “driver may notice smoke in their air vents or a cluster warning message prior to observing flames coming from the passenger side engine compartment area.”
Unlike some other recent recalls involving the risk of fire, Ford said this problem only occurs when the vehicle is being driven. Thus, there is no need to park the vehicle outside. And Ford did not recommend owners stop driving their Broncos until repairs are made. In June, it issued a “do not drive” order after recalling some Bronco and Maverick models due to suspension problems.
Which models are affected?
A 2025 Ford Bronco on the assembly line. The problem is caused by wiring harness damage.
The recall covers a total of 565,691 Bronco and Bronco Raptor models produced during the 2021 through 2026 model years. The smaller Bronco Sport is not covered by the recall.
The carmaker has received two warranty reports, three field reports and several other notifications related to the problem. The company said there have been no reported accidents or injuries, though 10 legal claims so far have been filed.
An initial notice was mailed out to owners on July 23 and Ford expects to follow up around August 24, once it has come up with a permanent fix. Owners will be advised to schedule service appointments with Ford dealers. Repairs will be made at no cost to owners.
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Another setback for Ford
Ford CEO Jim Farley has warned that Chinese automakers could pose an “existential threat” to established automotive brands.
Ford set an industry record with 153 separate recalls in 2025, those service actions affecting 12.9 million vehicles. It’s made more than 50 recalls so far this year, including four in July alone. Last week alone, over 670,000 Ford SUVs were recalled due to two separate safety issues. While the number of individual recalls in 2026 have come at a slower monthly pace, more than 10 million vehicles have so far been impacted, rapidly approaching last year’s total.
The automaker’s recalls have caused plenty of embarrassment for a company that long bragged in its ad campaigns that “Quality is Job 1.” According to Ford’s own data, it spent about $10 billion on warranty fixes and recall-related repairs last year. Those issues – including the widely publicized recall record – translated not only into higher costs but lower sales. Loyalty rates among existing owners fell, a particularly big issue because the industry mantra is that you spend about 11 times more to win a new buyer compared to the cost of maintaining an existing customer.
On the positive side, Ford may have finally found the right formula to get its quality under control. According to the closely watched 2026 J.D. Power Initial Quality Study, Ford handily topped all other mainstream brands while posting a near-record decline in reported “things-gone-wrong” this year. Analysts caution that IQS focused on vehicles during their first 90 days of ownership. It remains to be seen whether such an improvement will translate into better long-term reliability and reduced recalls.
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