Shock Absorber Failure On Certain 2021-2024 Ford Bronco SUVs

A potentially hazardous issue has been discovered in certain 2021-2024 Ford Bronco SUVs, prompting a recall. The rear shock absorbers in affected vehicles can corrode and fail, causing an external reservoir to detach from the vehicle and creating a road hazard. This problem can occur without warning, leaving drivers and passengers vulnerable to unexpected loss of control or accidents.

The issue came to light in October 2024, when the National Highway Traffic Safety Administration (NHTSA) contacted Ford regarding four complaints of failed long flange rear shock absorbers, three of which reported an external reservoir detachment. These initial reports were submitted through the NHTSA's Vehicle Owner Questionnaire (VOQ) system, which allows vehicle owners to report safety concerns and defects to the agency. In response, Ford's Critical Concern Review Group (CCRG) launched an investigation into the issue, focusing on 2021-2024 Ford Bronco vehicles equipped with long flange shock absorbers.

Through laboratory testing and analysis, the CCRG found that the long flange variant shock absorbers used in Ford Bronco vehicles were more prone to crevice corrosion than their short flange counterparts. This type of corrosion occurs when moisture becomes trapped between two metal surfaces, causing them to corrode over time. In the case of the Ford Bronco's rear shock absorbers, crevice corrosion can weaken the metal and lead to sudden failure, potentially resulting in an external reservoir detachment.

Further examination of returned parts confirmed this finding, with long flange variant shock absorbers showing significantly more corrosion than short flange variants. This suggests that the design or materials used in the long flange variant may be more susceptible to corrosion, increasing the risk of failure and external reservoir detachment. The CCRG's investigation also revealed that the problem is not limited to a specific region or climate, as reports of failed shock absorbers have been received from various parts of the country.

As of December 11, 2024, Ford has received a total of 554 reports related to this concern, including 551 warranty claims, one field report, and two customer complaints. These reports indicate that the problem is widespread and may be more common than initially thought. While there have been no reported accidents or injuries attributed to the shock absorber failure, the potential for harm is still present, and Ford is taking steps to address the issue as quickly as possible.

Although the final fix is still in development, Ford has begun notifying owners of the safety risk through interim letters mailed on January 28, 2025. These letters inform owners of the potential problem and advise them to be aware of any unusual noises or vibrations coming from the rear suspension. A second notice will be sent once the final remedy is available, which is expected to occur in the third quarter of 2025. At that time, owners will be instructed to take their vehicles to a Ford dealership for repair, where the defective shock absorbers will be replaced with new ones.

The recall affects certain 2021-2024 Ford Bronco SUVs and is identified by Ford's recall number 25S01 and NHTSA campaign number 25V-025. The recall is a precautionary measure to ensure the safety of drivers and passengers, as well as other road users who may be affected by a detached external reservoir. By addressing this issue proactively, Ford aims to prevent any potential accidents or injuries and maintain the trust of its customers.

The development of a remedy for the shock absorber failure is ongoing, with Ford working closely with its suppliers and engineering teams to design and test a new shock absorber that meets the company's safety and quality standards. The replacement parts are expected to be available in the third quarter of 2025, at which point owners will be notified to schedule an appointment with their local Ford dealership for the repair.