Ford Recalls 566,000 Bronco SUVs Over Engine Fire Risk From Wiring Harness Abrasion

On July 13, 2026, Ford's Field Review Committee made a decision that affects nearly every current-generation Bronco on the road: a safety recall of 565,691 vehicles due to an engine fire risk. The campaign covers model year 2021 through 2026 Bronco and Bronco Raptor SUVs built between September 2020 and June 2026. Because Ford sold roughly 589,000 current-generation Broncos through June, this recall captures approximately 96 percent of the entire production run.[6]

The root cause of the recall is a packaging oversight in the engine bay rather than a complex software failure. A wiring harness on the passenger side of the engine compartment lacks sufficient abrasion protection. As the vehicle vibrates during normal operation, the harness can rub against surrounding components, eventually wearing through its insulation and exposing bare copper wiring.[1][6]

When that exposed wiring shorts to ground, it can create electrical arcing. In the confined, heat-soaked environment of an engine compartment, this arcing can ignite nearby flammable materials. Ford began investigating the issue in June after identifying 15 incidents—including seven Bronco Raptor fires and eight base model fires—that may have originated from this specific harness between October 2024 and June 2026.[1]

Despite the massive scope of the recall, the actual danger is statistically narrow. Ford estimates that only about 1 percent of the recalled vehicles actually exhibit the chafing defect. The automaker has not received any reports of accidents or injuries related to the issue, but the recall blankets the entire population because there is no way to predict which specific harnesses will wear through first.[2][6]

The remedy for the defect is straightforward and mechanical. Dealership technicians will inspect the affected harness and install convolute plastic sheathing secured with abrasion tape to prevent further rubbing. This service will be performed entirely free of charge, addressing the root cause by adding the protection that was insufficient from the factory.[4]

For the half-million owners now holding the keys to a recalled SUV, the immediate question is what to do next. Ford has explicitly chosen not to issue a "do-not-drive" advisory, meaning the vehicles remain legally and operationally cleared for the road. The automaker advises owners to be vigilant for warning signs, which include smoke entering the cabin through the air vents or flickering dashboard warning lights.[3][4]

While official owner notification letters will not begin mailing until August 24, 2026, owners do not need to wait for the mail to take action. The complete 17-character Vehicle Identification Number (VIN) database is already live on the National Highway Traffic Safety Administration (NHTSA) website. Dealerships are expected to receive the official technical service bulletin and repair procedures by the end of July, allowing proactive owners to schedule their appointments early.[1][4]

This campaign highlights the engineering challenges of modern vehicle packaging, where miles of wiring must be routed through tight, high-vibration spaces. For Bronco owners, the situation requires balancing the statistical rarity of the defect against the severe consequences of an engine fire, shaping how they manage their vehicles in the weeks before a dealership bay opens up.[5][6]