The National Highway Traffic Safety Administration (NHTSA) has issued a rare and urgent "Do Not Drive" warning involving a very limited number of Ford Broncos—just three, to be exact. This extraordinary action was prompted by a manufacturing defect that left the front suspension bolts inadequately tightened. Specifically, the issue concerns the front lower control arms, which, if not securely fastened to the vehicle’s frame, could potentially detach while driving. This mechanical failure significantly increases the risk of losing control and crashing, making the defect extremely serious despite its limited scale.
The issue first surfaced in April when a Bronco owner reported an unusual and loud "pop" sound while making a sharp turn. After the SUV was brought to a dealership, a thorough inspection revealed that all the nuts holding the lower control arms to the frame were loose. Such a discovery raised immediate red flags and triggered a broader investigation.
Further examination uncovered a troubling oversight during the assembly process. According to the official recall documentation, the affected Bronco had initially failed an alignment test at Ford’s manufacturing plant. However, instead of undergoing the necessary revalidation through the factory’s automated alignment equipment, the vehicle was manually approved by a staff member identified as a “Quality Leadership System operator.” This meant the SUV left the plant without proper confirmation that its suspension components were securely fastened and correctly aligned—a critical lapse in quality control.
Ford has stated that, in total, only four vehicles may have been affected by this oversight. Fortunately, one of them was repaired before the recall notice was officially issued, leaving only three Broncos on the road that still need immediate attention. Though this may seem like an incredibly small number, the potential consequences are significant enough to warrant serious action.
The recall affects vehicles from both the 2024 and 2025 model years. In response, Ford is contacting the owners through multiple channels including phone calls, emails, and physical mail. Owners of the possibly affected Broncos are being instructed not to drive their vehicles under any circumstances. Ford is offering complimentary towing services to transport the SUVs to authorized dealerships, where technicians will inspect the control arm fasteners. Any loose bolts will be properly tightened or replaced, and the vehicle’s alignment will be rechecked and corrected as needed.
If you suspect your Bronco might be involved in this recall, it is essential to stop driving it immediately. Owners can verify their vehicle’s status by checking the VIN against the NHTSA’s recall database. With Ford reaching out proactively, affected drivers are likely already receiving notifications urging them to keep their Broncos off the road until the issue is resolved.