Ford has issued a recall affecting 149,449 Bronco SUVs from model years 2021 to 2024 due to a critical issue with the rear suspension that could result in parts detaching while driving. The recall specifically targets Badlands and Sasquatch models, which are equipped with remote-reservoir rear dampers that may corrode over time, leading to potential failure.

Ford Bronco Recall Highlights

• Ford recalls 149,449 Broncos (2021–2024 Badlands, Sasquatch)
• Corrosion can cause weld failures, leading to bouncing, noises, or detaching parts.
• Newer Broncos use redesigned dampers, but no fix yet for recalled models.
• Recall notices start Feb. 7, 2025, with repairs still in development.

The Issue: Corrosion Leading to Failure

According to Ford’s filing with the National Highway Traffic Safety Administration (NHTSA) on January 25, 2025, approximately 30% of affected vehicles may develop the issue. Corrosion between the external reservoir, mounting flange, and damper body can lead to excessive pressure buildup, potentially causing weld failures and the reservoir tube detaching. This can result in excessive bouncing, strange noises, and in severe cases, detached components becoming road hazards for other motorists.

The issue first came to NHTSA’s attention in October 2024, when four Bronco owners reported problems with their rear dampers. Three of those owners claimed the remote reservoirs had detached. Ford launched its own investigation in November and determined that the long-flange design used in these dampers was particularly vulnerable to corrosion.

Ford has since switched to a short-flange damper design for newer Badlands and Sasquatch models, stating that this updated component is less prone to corrosion-related failures. However, a repair plan for already-affected vehicles has not yet been finalized.

What Owners Need to Know

At this time, Ford has not issued a recommended action for affected Bronco owners beyond monitoring their vehicles for symptoms such as leaking shock oil, unusual suspension behavior, or loose components. Official recall notifications are scheduled to begin on February 7, 2025.

Ford states that a fix is in development, but until a solution is confirmed, Bronco owners may want to avoid extreme off-road conditions that could accelerate wear on the rear suspension components.

Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 25S01.

A PDF version of the NHTSA Recall Report can be found here. 

A PDF version of Ford’s official recall mailer can be found here.