A wiring harness that rubs itself raw and starts fires. That’s the problem Ford just disclosed across nearly 566,000 Bronco SUVs spanning model years 2021 through 2026, a production run stretching from September 2020 to June 2026. The fix is plastic sheathing and abrasion tape.
Ford estimates roughly 1% of the recalled vehicles carry the defect, but the automaker’s own Critical Concern Review Group found 15 fire incidents that may trace back to the same root cause: insufficient protection on the engine compartment wiring harness, which chafes against surrounding components over time until bare copper is exposed. A short circuit follows. Then arcing. Then flames licking out from the passenger side of the engine bay while someone is driving.
The wiring harness came from Aptiv, the Tier 1 supplier that conveniently spun off its electrical division as a separate company called Versigent on April 1. Whether that corporate restructuring insulates Aptiv from liability claims is a question lawyers are probably already asking.
Ford’s investigation kicked off June 18 after its review group noticed a pattern in reported fires. Customers described smoke pouring from the air vents, then flames visible on the passenger side. The team inspected more than 80 Broncos and found rubbing and chafing evidence on the harness in a handful of them.
Computer modeling and vibration testing followed, revealing that Bronco Raptor models, with their beefed-up suspension and different physical architecture, were more susceptible to the problem than base trims. Seven Raptor fires and eight base model fires were flagged.
The timeline of known incidents runs from October 2024 to June 2026. Ford says it is aware of two warranty reports, three field reports, one customer service case, four owner questionnaires filed with NHTSA, and 10 legal claims. No injuries reported. No accidents reported. Ford is lucky that column stays at zero.
The fix itself is not complex. Dealers will wrap the harness with protective covering to prevent future chafing. Ford says it has already introduced an improved protective sleeve on current production Broncos. Notification letters go out starting August 24.
Six model years of production with the same vulnerability is a long time for a wiring harness to go underprotected. The Bronco launched in mid-2020 as Ford’s triumphant return to the off-road SUV segment, and it has been a genuine sales success. But a vehicle designed to be bounced over rocks and ruts needs wiring that can handle the vibration.
Ford’s own testing confirmed that the Raptor, the model most aggressively marketed for off-road punishment, was the variant most prone to the problem. That’s not a great look for a truck sold on its ability to take a beating.
This recall lands on a pile of others. In just the past six weeks, Ford has recalled 388,000 SUVs for binding seat switches, 741,000 SUVs and pickups for rollaway risk, and over 548,000 Expeditions for a center console trim hazard. The Bronco itself was recalled last November for blank instrument clusters.
Ford’s quality costs continue to mount at a time when the company is trying to cut billions in expenses. Ford’s Field Review Committee approved this recall on July 13. Owners who notice smoke from their vents before the fix arrives should probably not wait for the letter.
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