Bronco Brakes Failed: Known Issue?

Oly

Dec 12, 2021

So I almost died driving my 4 door Outer Banks on the freeway the other day. My wife and I were driving out to Hilton Head for a 10k. Everything was great until…Some jerk swerved in front of me to avoid being behind a semi truck chugging uphill.

This is where I almost died…
When I went to hit the brakes the pedal was impossible to press, the Bronco’s dashboard lit up saying something like brake error: check brake system. I luckily was able to slow down by using the manual shift selector on the side of the gear shift and basically standing on the brake pedal and immediately pulled over. I got out and checked the brakes after turning the car off and on. The brake pedal was now able to depress, but the brakes were super spongey. I drove to the closest Ford dealership and had them check it out. The tech came back after a few min and said it was a known issue with the Brake Vacuum and it has to come from Michigan.

This just happened so I’m getting more info as they can’t order the part until tomorrow, but I’ll update as I have more info.

I know 1st gen products have issues but this one is a really big problem. Good thing I wasn’t on the trail next to a cliff otherwise I wouldn’t be here.

Driving 70 mph on the freeway and you go to hit the brakes and there are none… scared the crap out of me. Driving a rental and now I have PTSD every time I brake.

Anyone else heard of this for the 4doors? I know the sport had a brake recall, but not 100% sure this is the same issue?

Babytruck, AD BRONCO

Last edited by a moderator: Dec 12, 2021

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Apr 27, 2022

#20

RobS1964
Black diamond. Sasquach pkg. 2.7 engine. Automatic transmission.
Also first time driving at higher elevation - no idea if relevant but it is a change....

2.7 has electronic assisted brakes. While 2.3 has vacuum, so different root cause but similar effects.

2021 badlands, 2.3, MT, rapid red, soft top

Apr 27, 2022

#21

My dealer diagnosed remotely the root cause after running OASIS scan. 2.3 Manual high package.

Sammy and the gang at Glenwood Springs Ford were awesome. Squeezed me in and got the part shipped from Denver and repaired in less than 24 hours. Ford took care of the tow and costs.

I am disappointed this happened, but glad it seems to be fixed. I know that electronics fail. It’s absolutely a known issue. I do not know recall criteria, but this sure seems to fit the criteria!

This is a snip from 6G, there are a couple long threads over there.

2021 badlands, 2.3, MT, rapid red, soft top

Bronco 202?, NT AUTOMOTIVE

Apr 28, 2022

#22

Jboohound
It's 2022 and we're having issues with brakes, transmissions, faulty tops, electronics, et al... sexy ride and all but is the Bronco ready for prime time?

careful… you maybe attacked. You know about the fan boys.

Babytruck, Jboohound

May 01, 2022

#23

My 22 is still problem free. Absolutely love my Bronco. I almost have 1600 miles on it so still low miles compared to some. Hoping the problems are worked out and I continue to just enjoy the ride!

2022 Bronco Black Diamond 2dr 2.3L manual Hot Pepper Red. Reserved 8/7/20. Ordered 1/23/21. Reordered 10/08/21. Scheduled week of January 24th 2022, delivered 2/24/2022

Deano Bronc, Sven

Jul 16, 2024

#24

Shoresy
My dealer diagnosed remotely the root cause after running OASIS scan. 2.3 Manual high package.

Sammy and the gang at Glenwood Springs Ford were awesome. Squeezed me in and got the part shipped from Denver and repaired in less than 24 hours. Ford took care of the tow and costs.

I am disappointed this happened, but glad it seems to be fixed. I know that electronics fail. It’s absolutely a known issue. I do not know recall criteria, but this sure seems to fit the criteria!

This is a snip from 6G, there are a couple long threads over there.

Same issue different dealer outcome. I got all these codes and reported to me dealer. Asked them to order replacement part. Was told THEY had to diagnose and then they would order the part.
3 1/2 months before my appointment I have figured out how to make it NOT have a firm pedal is my only rig so I keep driving.
9 am appointment with a 2 hour drive to be there. Don't get the Bronco in till13:00. 14:00 come out and say yup..you were correct and we will order the part but....it's on national back order and since it's a safety issue you must leave the Bronco.
I took the Bronco home after stating I've been driving for over 5k miles waiting for this visit and if the tech didn't eff up my ride I'll be fine.
They will call me when the part arrives. 1 month, another month nope still on back order.

I call the parts department at the same dealership with the updated hose assy # and they have one in stock. I buy it with points pay for shipping and fix my Bronco the next day in 20 minutes.
They told me to take it to the dealership I bought it from from now on for service. Hello...this IS where I bought it.
Needless to say I now drive 2 hours the other direction to Idaho for service work.

This was July 2022...Today 20k more trouble free miles. Stay away from Kendall Ford in Bozeman MT.

21 Badlands, 2 dr, four banger, slushbox, SAS. PERFECT!

UserError, PSUTE

Jul 17, 2024

#25

Sven
Same issue different dealer outcome. I got all these codes and reported to me dealer. Asked them to order replacement part. Was told THEY had to diagnose and then they would order the part.
3 1/2 months before my appointment I have figured out how to make it NOT have a firm pedal is my only rig so I keep driving.
9 am appointment with a 2 hour drive to be there. Don't get the Bronco in till13:00. 14:00 come out and say yup..you were correct and we will order the part but....it's on national back order and since it's a safety issue you must leave the Bronco.
I took the Bronco home after stating I've been driving for over 5k miles waiting for this visit and if the tech didn't eff up my ride I'll be fine.
They will call me when the part arrives. 1 month, another month nope still on back order.

I call the parts department at the same dealership with the updated hose assy # and they have one in stock. I buy it with points pay for shipping and fix my Bronco the next day in 20 minutes.
They told me to take it to the dealership I bought it from from now on for service. Hello...this IS where I bought it.
Needless to say I now drive 2 hours the other direction to Idaho for service work.

This was July 2022...Today 20k more trouble free miles. Stay away from Kendall Ford in Bozeman MT.

Curious was it the vacuum hose,the vacuum manifold, the vacuum tube or a combination. I'm going to order and keep these parts I'm my Bronco just in case. Brakes are a non negotiable for me and I like to drive on some serious twisties along the coast.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Jul 17, 2024

#26

OrangecrushBronco
Curious was it the vacuum hose,the vacuum manifold, the vacuum tube or a combination. I'm going to order and keep these parts I'm my Bronco just in case. Brakes are a non negotiable for me and I like to drive on some serious twisties along the coast.

It was a vacuum hose assembly. Connected to three different points. What I found was when the engine was under load say cruise control...the pedal was almost impossible to press. Take it off cruise and normal pedal. Then i tried to apply the brakes while accelerating same issue. let off the throttle normal brakes.
Was still spooky when the dash lit up like a Christmas tree and no brakes till I figured it out. Drove over 5000 miles waiting for the dealer, just never used cruise.

21 Badlands, 2 dr, four banger, slushbox, SAS. PERFECT!

OrangecrushBronco

Jul 17, 2024

#27

Sven
It was a vacuum hose assembly. Connected to three different points. What I found was when the engine was under load say cruise control...the pedal was almost impossible to press. Take it off cruise and normal pedal. Then i tried to apply the brakes while accelerating same issue. let off the throttle normal brakes.
Was still spooky when the dash lit up like a Christmas tree and no brakes till I figured it out. Drove over 5000 miles waiting for the dealer, just never used cruise.

Thanks for the info. I don't really use Cruise Control but still very good to know and seeing your post may save a life. It's a cheap enough part that I'm going to keep one in my truck. If I have it I'll be less likely to need it and if I do it's an easy roadside fix provided I have the part.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Sven

Jul 17, 2024

#28

Sven
It was a vacuum hose assembly. Connected to three different points. What I found was when the engine was under load say cruise control...the pedal was almost impossible to press. Take it off cruise and normal pedal. Then i tried to apply the brakes while accelerating same issue. let off the throttle normal brakes.
Was still spooky when the dash lit up like a Christmas tree and no brakes till I figured it out. Drove over 5000 miles waiting for the dealer, just never used cruise.

Thanks @Sven ! I presume this is what you're referring to?

I'm going to add this to my preparedness kit.

Supreme Leader of the Wandering but NOT Lost
2022 OBX Cyber Orange Metallic with random acutriments.

Jul 17, 2024

#29

OrangecrushBronco
Thanks @Sven ! I presume this is what you're referring to?
I'm going to add this to my preparedness kit.

That's the dude. Took about 20 minutes to change.
Just my thought...if you are going to order the updated line I would just install it and save the current one for the back up.

21 Badlands, 2 dr, four banger, slushbox, SAS. PERFECT!

Sam I Am 1966, OrangecrushBronco

Jul 17, 2024

#30

OrangecrushBronco
Thanks for the info. I don't really use Cruise Control but still very good to know and seeing your post may save a life. It's a cheap enough part that I'm going to keep one in my truck. If I have it I'll be less likely to need it and if I do it's an easy roadside fix provided I have the part.

Not so much a cruise issue as when the engine is pulling a vacuum AKA under load....just let off the throttle and the brakes worked normal. At least for me.

21 Badlands, 2 dr, four banger, slushbox, SAS. PERFECT!

OrangecrushBronco

Aug 01, 2024

#31

I've also had brake issues a couple times when off-roading - the dash lights up with ABS lights, traction control failure, won't let me change goat mode, and "service brakes" error messaging. turn it off, disconnect the battery, reconnect it, and everything is fine.

The worst situation was when I was on a shelf road and realized I needed to turn around, so I started making a multi-point turn, and as I was facing the ledge of the shelf road, the brake pedal went to the floor... I quickly pumped it and pressure came back... scared the crap out of me.

Reservation: 7/20/20 | MY '21 order: 2/1/21 | MY '22 order: 10/22/21 | Blend 8/5, built 8/8, 'built' status 8/27, in my driveway 10/12/22
Auto Photographer in Sacramento CA:
www.instagram.com/photographybymarkbrooks

Jakob1972, Deano Bronc

Aug 01, 2024

#32

Calgecko
I've also had brake issues a couple times when off-roading - the dash lights up with ABS lights, traction control failure, won't let me change goat mode, and "service brakes" error messaging. turn it off, disconnect the battery, reconnect it, and everything is fine.

The worst situation was when I was on a shelf road and realized I needed to turn around, so I started making a multi-point turn, and as I was facing the ledge of the shelf road, the brake pedal went to the floor... I quickly pumped it and pressure came back... scared the crap out of me.

do you have the 2.3L or the 2.7L
I don't drive the Bronco all the time but the last few times I did the pedal felt like I had to push it farther than normal for the brakes to start to grab. The Pads look fine too. The wife (her daily) says it feels normal to her. hmmm maybe Ill just get the new vacuum line.

Bronco Nation 1100. Everglades, Desert Sand
Res: 7/30/20 ordered 1/22/21 reorder 10/15/21 changed to Everglades 3/9/22 schedule 8/29/22 bumped to 9/5; 9/7/22 blend, 9/9 Mods, 9/26/22 completed, 10/7 shipped, 11/3/22 delivery

Sven

Aug 07, 2024

#33

Jakob1972
do you have the 2.3L or the 2.7L
I don't drive the Bronco all the time but the last few times I did the pedal felt like I had to push it farther than normal for the brakes to start to grab. The Pads look fine too. The wife (her daily) says it feels normal to her. hmmm maybe Ill just get the new vacuum line.

2.7

Jakob1972

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