Low pressure fuel pump failure - recall

[Bronco Lou]

I had a fuel pump fail on me back in 2023 while I was out in the Nevada desert exploring some old mining and BLM fire break roads in my 2022 Badlands. The tow truck driver was able to get to where I was and get turned around enough so he could pull me up onto his flat bed. When I got to my Ford dealer in Vegas, I asked the Service Tech if he had seen any other bad fuel pumps on Broncos and he told me that up to that time, mine was the fourth. My question is, does Ford know the particular Lot Numbers that these bad fuel pumps fall into and do the dealers keep track of the Lot Numbers of the new ones that are replacing the bad ones?

In automotive not so much. In airlines most mechanical and electronic parts are serial numbered and traceable to the point where even the individual in charge of final production can be traced.

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[BigJim1957]

The same in the Air Force. When I worked QA in Alaska, we had to track and report all the failures of our high-power HF transmitter tubes and klystrons for our heavy SATCOM terminals to the Air Force Communications Command for Trend Analysis purposes. These reports included manufacturers, serial numbers, lot numbers, and number of hours on-line to determine if the items fell below the manufacturer's MTBF rates. If they did fall below the standard, the Air Force would recall all of the tubes and klystrons in the supply system with those lot numbers and return them to the manufacture for direct replacement.

 

[DUSTYcazOREGON]

My written mail USPS for this recall arrived today.

 

[Roger123]

My written mail USPS for this recall arrived today.

Mine came last week and it was printed in two languages, nice!

It was like adding salt to the would though as my Bronco was in the shop and had just been deemed a total loss........

It's like right after your dog dies getting a note from the vet that it's time for Spot's annual check-up........

 

[BroncoAZ]

So what is safe out there to buy these days? there is a risk in any make, model you buy- it's the luck of the draw- you may or may not get a good vehicle. It depends on the defect, could have been multiple suppliers making the part and one had a defect, it went undetected and got assembled.

I used to run a fleet of 150 GM trucks for a construction company. The 2019 with 8 speed and anything 2018-2021 with a 5.3L or 6.0L gas were ticking time bombs. As a fleet customer they would frequently do stuff for us as goodwill, but in 2023 I had 9 engines and 5 transmissions replaced. When I left mid 2024 we were already at 8 engines for the year. There were issues before Covid, then they just got worse.

My 2024 Tesla Y has been flawless. My 2024 Lightning certainly won’t have this fuel pump issue . Toyota used to be the safe bet go to, but since they went to turbocharged small displacement engines they are having some issues. I would guess the new Landcruiser, 4 runner, or GX550 are good to go since they are made in Japan. The new Prius has a redesigned engine, supposed to be a major improvement over the last generation.

My 2021 Bronco has been great, but I only have 6700 miles in 3 years.

 

[JT58Bronc]

I used to run a fleet of 150 GM trucks for a construction company. The 2019 with 8 speed and anything 2018-2021 with a 5.3L or 6.0L gas were ticking time bombs. As a fleet customer they would frequently do stuff for us as goodwill, but in 2023 I had 9 engines and 5 transmissions replaced. When I left mid 2024 we were already at 8 engines for the year. There were issues before Covid, then they just got worse.

My 2024 Tesla Y has been flawless. My 2024 Lightning certainly won’t have this fuel pump issue . Toyota used to be the safe bet go to, but since they went to turbocharged small displacement engines they are having some issues. I would guess the new Landcruiser, 4 runner, or GX550 are good to go since they are made in Japan. The new Prius has a redesigned engine, supposed to be a major improvement over the last generation.

My 2021 Bronco has been great, but I only have 6700 miles in 3 years.

Wow and I thought I had low miles on my 2022 Bronco I have owned for 3 years and 4 months, with 16,200 miles.

I had a 2019 Chevy Silverado Double Cab, 4 X 4 LD Work truck- the old style leftover previous Gen, so it was really a 2018. Base, even had the lever for the 4 X 4 shifter, LOL. It had the 5.3 with the 6 speed transmission though, not the 8 speed. 0 issues, no recalls in 3 years I owned it. A great truck. I traded it in on the Bronco, was hesitant but after waiting 2 years I had to have the Bronco.

LOL my wife and I were thinking to trade in the Bronco and my current daily driver- a 2023 Chevy Colorado with the 2.7 (non turbomax light duty engine) for a new Chevy LT Trail Boss. But reading about the 6.2 and 5.3 engine issues. And the 2.7 turbomax in such a huge truck, we decided to hold off. The Colorado has been great so far and even with all of the recalls the Bronco has been great too.

 

[BroncoAZ]

Wow and I thought I had low miles on my 2022 Bronco I have owned for 3 years and 4 months, with 16,200 miles.

I had a 2019 Chevy Silverado Double Cab, 4 X 4 LD Work truck- the old style leftover previous Gen, so it was really a 2018. Base, even had the lever for the 4 X 4 shifter, LOL. It had the 5.3 with the 6 speed transmission though, not the 8 speed. 0 issues, no recalls in 3 years I owned it. A great truck. I traded it in on the Bronco, was hesitant but after waiting 2 years I had to have the Bronco.

LOL my wife and I were thinking to trade in the Bronco and my current daily driver- a 2023 Chevy Colorado with the 2.7 (non turbomax light duty engine) for a new Chevy LT Trail Boss. But reading about the 6.2 and 5.3 engine issues. And the 2.7 turbomax in such a huge truck, we decided to hold off. The Colorado has been great so far and even with all of the recalls the Bronco has been great too.

The 2.7 Turbomax in the 1500 is plenty of power, I put 15 of them in the fleet in 2023 and 2024. They are not really any better on fuel than the 5.3L unless you drive like you’re driving Miss Daisy. My favorite engine in those is the 3.0L diesel. I had a 2021 and a 2022 as my personal work truck from 2021-2024. Great power and torque, the 10 speed transmission is well sorted, and I was averaging 27 mpg overall in 100K miles across the two trucks. Unloaded on the highway at 70 mph I was getting 30-32 mpg and 650+ miles per tank, towing a 16’ enclosed trailer (7000#) I was getting 17-19 mpg. The 5.3L trucks were 20-21 mpg unloaded and 10-12 towing the same load. Each 1500 diesel I put in fleet service (about 15 trucks 2021-2024) was saving $7K in fuel to 100K miles and only cost $1K more to buy. The guys who got them loved them. I would buy the diesel with a long extended warranty without hesitation, then sell it before the warranty is up. Repairing diesels out of warranty is $$$$$$$.

 

[JT58Bronc]

The 2.7 Turbomax in the 1500 is plenty of power, I put 15 of them in the fleet in 2023 and 2024. They are not really any better on fuel than the 5.3L unless you drive like you’re driving Miss Daisy. My favorite engine in those is the 3.0L diesel. I had a 2021 and a 2022 as my personal work truck from 2021-2024. Great power and torque, the 10 speed transmission is well sorted, and I was averaging 27 mpg overall in 100K miles across the two trucks. Unloaded on the highway at 70 mph I was getting 30-32 mpg and 650+ miles per tank, towing a 16’ enclosed trailer (7000#) I was getting 17-19 mpg. The 5.3L trucks were 20-21 mpg unloaded and 10-12 towing the same load. Each 1500 diesel I put in fleet service (about 15 trucks 2021-2024) was saving $7K in fuel to 100K miles and only cost $1K more to buy. The guys who got them loved them. I would buy the diesel with a long extended warranty without hesitation, then sell it before the warranty is up. Repairing diesels out of warranty is $$$$$$$.

Thanks- I really appreciate the tip on the 3.0 diesel. I was very hesitant due to the extra cost for the diesel. For high miles in a short time you do re-coup the cost, you have done your homework on the math. For shorter overall mileage there was not much savings for me. I test drove the 5.3 and 2.7 in the Silverado Trail Boss- the 5.3 seemed so much peppier. It could be the 10 speed transmission versus the 8 speed. BTW I get 650 miles per tank on my 2023 Colorado- it is 2WD, unloaded. I wish the Bronco had that range LOL. On the rare occasion when I drive it to work I have to gas it up every 3 days- kind of a pain with the small gas tank.

 

[BroncoAZ]

Thanks- I really appreciate the tip on the 3.0 diesel. I was very hesitant due to the extra cost for the diesel. For high miles in a short time you do re-coup the cost, you have done your homework on the math. For shorter overall mileage there was not much savings for me. I test drove the 5.3 and 2.7 in the Silverado Trail Boss- the 5.3 seemed so much peppier. It could be the 10 speed transmission versus the 8 speed. BTW I get 650 miles per tank on my 2023 Colorado- it is 2WD, unloaded. I wish the Bronco had that range LOL. On the rare occasion when I drive it to work I have to gas it up every 3 days- kind of a pain with the small gas tank.

You really need to get into the boost to make the Turbomax trucks to feel peppy, but that kills the MPG. Full throttle comparison on both it wouldn’t shock me if the turbomax were faster to 60.

I was going to buy myself a 1500 diesel end of last year. I found a killer lease deal on the 2024 Lightning, $11,300 all in for a 3/36 lease. I realized my home solar way putting out enough excess for another EV so I pulled the trigger. Cheap payment and no fuel bill is saving me thousands per year. I love the instant torque and savage acceleration on the Lightning. My wife has a Tesla Y which is also a good fit for us. I still have ICE vehicles at the house (21 Bronco, 22 Highlander, 01 Expedition) but the EV’s are great daily drivers for us.

 

[ex_nyer]

Lots of calls, fewer fixes available!

Don't forget the windshield recall?

 

[Dral97]

Got this not long ago. I have been getting some lag, though it's been hot and I wonder if it's the AC going.

Anyway, was going to take the Bronco down to OBX. The recall says the problem could be worse in hot weather, so looks like the Bronco is staying home.

 

[ThunderFlash]

So, had just got off the trails today in our '22 WT (built 12/21) to head home and the check engine light comes on and she lost power. Got off the road and she died....Found On Road Dead. Auto start was disabled, but dash said "manual restart required". She would crank with gusto, but only sputter a bit and weakly fire. As soon as the starter motor quit, she'd die. Cell service was limited where we were at, so the app was not helpful. After a frustrating bout with AAA, we found our own tow truck company and got it hauled home 4 hours later.
Got it off the truck, and I'll be damned if it didn't start after a longer than normal crank session, but she died as soon as she got in the garage. The exhaust had a very odd smell to it, like old varnished gas would have. It's not old gas and it ran fine for the first half of the tank.
Now we are home, the app is giving the information below about low fuel level, but it's got more than a half tank. It actually started on a slight up hill grade, then died in the flat garage.
@Ducati1098, would you suspect this could be the LP fuel pump? I do have the recall notice. I just didn't want to take it to a dealer and have it sit for weeks because there is no resolution to the recall. Do you think they'd prioritize me with an inoperable vehicle?
It was a bummer conclusion to a great day on the trails, but it would have been FAR WORSE if it had happened an hour earlier! That tow truck wasn't making it up Door Bender, and I sure as heck wasn't pushing it!
Tomorrow I'll read any stored codes. I may put it on a trickle charger, too, as the voltage was only a 12.5V after cranking several times. This all started cruising at 45 mph, so I wouldn't think it's the battery, but Broncos seem sensitive to voltage.

 

[Ducati1098]

@Ducati1098, would you suspect this could be the LP fuel pump? I do have the recall notice. I just didn't want to take it to a dealer and have it sit for weeks because there is no resolution to the recall. Do you think they'd prioritize me with an inoperable vehicle?

Sure sounds like fuel pump is a possibility. Hard to say for sure without diagnosis.

If it is the pump, and as far as prioritizing the repair, I looked up the current 2dr fuel pump and Ford still shows plenty of stock right now. There’s nothing to suggest a stop sale on the current part or anything like that.

Obviously we don’t know what the exact recall repair is yet, but any dealership should still be able to order the most current part number and have it replaced pretty quickly. It won’t close the recall or anything and that will still likely need to be done when it’s released, but it will get you back on the road if that’s the cause.

 

[ThunderFlash]

Sure sounds like fuel pump is a possibility.

Threw codes P008A, P00C6, and P0301, both with and without a "(00)". I assume that's left and right banks? Everything seems to be pointing to the LP fuel pump. I guess I'd rather have a common, known problem than some form of unique sporadic mystery glitch.

 

[Ducati1098]

Threw codes P008A, P00C6, and P0301, both with and without a "(00)". I assume that's left and right banks? Everything seems to be pointing to the LP fuel pump. I guess I'd rather have a common, known problem than some form of unique sporadic mystery glitch.

Yeah P0301 is a misfire, but that’s just likely due to low fuel pressure. The numbers or letters after a code is the condition code. Those don’t really matter for these codes.
Definitely seems like the fuel pump based off those.

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