In a staggering oversight, Ford has announced a recall of 149,449 Bronco SUVs from model years 2021 through 2024 due to a critical defect in the rear Bilstein shock absorbers. Premature corrosion leading to potential detachment of essential suspension components, a failure that endangers not only Bronco drivers, but everyone sharing the road with them.
The build date timespan to look out for is 9/30/2020 to 7/23/2024 on your driver’s side door jamb label. During this span, Bilstein supplied Ford with a rear damper for the Badlands and Sasquatch optioned Broncos that included an external reservoir as part of its End Stop Control Valve (ESCV) system.
According to the National Highway Traffic Safety Administration (NHTSA), the defect originates from corrosion between the external reservoir, damper body, and mounting flange on the long-flange rear shocks. This corrosion exerts undue stress, causing excessive wear and ultimately leading to the external reservoir tube breaking free.
The recall encompasses all Bronco body styles, with a particular focus on the Badlands trim equipped with “Capable Suspension” and models featuring the Sasquatch package. Notably, Ford transitioned from a long flange to a short flange assembly on Badlands vehicles in May 2024 and on Sasquatch-equipped SUVs in July 2024—a tacit acknowledgment of the flaw’s severity.
Despite 551 warranty claims, two customer reports, and one field report related to this defect, Ford astonishingly reports no known accidents or injuries. Dealer notifications have already begun, with owner notifications slated to start on February 3. However, in a move that leaves Bronco owners in the lurch, Ford admits that “a remedy is under development,” offering no immediate solutions or guidance for concerned drivers.
This recall is just the latest in a series of quality control failures for Ford. The company recently recalled over 270,000 Broncos and Mavericks due to a separate issue causing unexpected power loss, linked to defective 12-volt batteries. Additionally, Ford faced scrutiny over engine failures in various models, including the Bronco, leading to a recall of approximately 91,000 vehicles and an extended warranty program.
