October 20, 2022 NHTSA CAMPAIGN NUMBER: 22V787000
An engine stall can increase the risk of a crash.
NHTSA Campaign Number: 22V787
Manufacturer Ford Motor Company
Components FUEL SYSTEM, GASOLINE
Potential Number of Units Affected 26
Ford Motor Company (Ford) is recalling certain 2022 Bronco Sport vehicles. The fuel pump control module (FPCM) bracket may not be secured to the fuel tank assembly, which can lead to FPCM failure and cause an engine stall.
Dealers will replace the fuel tank, free of charge. Owner notification letters are expected to be mailed December 5, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 22S66.
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
|Vehicle||Model Year||Assembly Plant||Build Dates|
|Bronco Sport||2022||Hermosillo||August 10, 2022 through August 11, 2022|
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS SAFETY RECALL
In all of the affected vehicles, the Fuel Pump Control Module (FPCM) bracket that secures the module to the fuel tank may become detached. If the FPCM bracket is not secured to the fuel tank, pulling stress is applied to the FPCM wiring harness connector, and over time pulling stress of the FPCM connector may lead to a loss of the electrical connection resulting in a non-functional FPCM. Alternatively, the FPCM may become damaged due to continued impacts against the body of the vehicle and the fuel tank, resulting in a non-functional FPCM. When driving on a bumpy road, the customer may experience a clunk type noise from under the rear seat of the vehicle. A non-functional FPCM prevents fuel from being supplied to the engine, potentially resulting the Malfunction Indicator Light (MIL) to illuminate and a sudden loss of motive power to the vehicle, increasing the risk of crash.
DO NOT DEMONSTRATE OR DELIVER any new in-stock vehicles involved in this safety recall. A complete Dealer Bulletin will be provided to dealers the week of November 28, 2022 when it is anticipated that parts ordering information and repair instructions will be available to support this safety recall.
IMPORTANT: Dealers should open a Repair Order (RO) only when a full dealer bulletin is published. Opening an RO against an Awareness or Advance Notice will result in warranty rejections against a recall.
Owners of record will be notified via first-class mail after repair instructions and parts ordering information have been provided to dealers.
Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Correct all vehicles in your new vehicle inventory prior to delivery.
On August 11, 2022, a technician at Hermosillo Assembly Plant (HSAP) reported that they could not install the Fuel Pump Control Module on the fuel tank of a 2022MY Bronco Sport because the plastic attachment bracket where it mounts was detached. The HSAP team initiated a material inspection of incoming fuel tanks and identified additional occurrence of a detached FPCM bracket. An In-Transit Stop Ship was issued on August 17, 2022, to contain suspect vehicles that had been shipped from the plant. Ford reviewed Plastic Omnium weld pad thickness control chart for the blow molded fuel tank to determine the population of affected parts. They determined the issue started on August 5, 2022 at Plastic Omnium when an operator adjusted the die gap manually.
August – September 2022: Automotive Safety Office searched for and monitored field reports to determine scope of which vehicles may be affected.
On October 13, 2022, Ford’s Field Review Committee reviewed the concern and approved a field action.
Ford is not aware of any reports of accident or injury related to this condition.
Ford is not aware of any VOQ’s, and there are no warranty reports related to this condition.
1 Affected Product
6 Associated Documents
Defect Notice 573 ReportRCLRPT-22V787-5657
Recall 573 Report – 10/20/22
Manufacturer Notices(to Dealers,etc) – Advance Notice re NEW VEHICLE DEMONSTRATION / DELIVERY HOLD – Advance Notice – Safety Recall 22S66 Certain 2022 Model Year Bronco Sport Vehicles Fuel Tank ReplacementRCMN-22V787-6842
Recall 573 Report – 10/20/22RCLRPT-22V787-3107
Recall 573 Report – 10/25/22RCLRPT-22V787-3816
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