Ford has issued a recall for 149,449 Bronco SUVs due to a defect in the rear suspension that could cause parts to detach. The recall applies to 2021-2024 Bronco Badlands models and those equipped with the off-road-focused Sasquatch package, both of which feature rear dampers with remote reservoirs that are prone to corrosion.

According to the recall report submitted to the National Highway Traffic Safety Administration (NHTSA) on Jan. 25, the carmaker estimates that approximately 30% of affected units may experience this issue. The corrosion can lead to excessive bouncing, unusual noises, and, in some cases, complete detachment of the external reservoir from its mounting point.

The problem reportedly stemmed from the rear damper's long-flange design, which Ford has identified as particularly vulnerable to corrosion between the reservoir, the mounting flange, and the damper body. Over time, a buildup of corrosion can create a jacking force that erodes the weld and surface material, ultimately causing the reservoir tube to separate.

According to the NHTSA, due to the defect, car owners will experience some warning signs like a bouncy ride, noise, or leaking fluid by the rear wheels before a major issue with the external reservoir could happen. 

The NHTSA launched an investigation into the issue in October 2024 after receiving four complaints from Bronco owners, three of whom reported that the remote reservoir had detached.

Ford began its own inquiry in November and determined that the long flange was the primary factor behind the corrosion problem. As a result, the company transitioned to a short-flange damper design, which has shown improved resistance to corrosion in newer models.

Ford has not yet developed a remedy for vehicles covered by the recall; it will announce it once it has finalized what to do to address the problem. Bronco owners will receive notifications regarding the investigation by Feb. 7.

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