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Ford $F Motor Company has issued a "Do Not Drive" recall covering 4,653 Bronco Sport and Maverick vehicles, warning owners to stop driving immediately due to a potential suspension defect that could cause loss of vehicle control.
Designated 26S36, the recall encompasses 2,296 Bronco Sport units from model years 2021 through 2026, along with 2,357 Maverick units spanning 2022 through 2026. According to Ford, a manufacturing error at the assembly stage — either an incorrect installation or a faulty in-plant repair — left some front lower control arm ball studs only partially seated in the wheel knuckle. A separation of the ball joint during driving could rob the driver of steering control, raising the likelihood of a crash, Ford said.
The defect produces no advance warning signs, and Ford has said it has not received any reports of crashes or injuries attributable to the issue.
The automaker traced the issue to its Hermosillo Stamping and Assembly Plant. For vehicles built before June 1, 2025, assembly plant operators may not have fully inserted the front lower control arm ball stud into the wheel knuckle before tightening an associated pinch bolt. Ford said that prior to a process change implemented on June 1, 2025, the assembly station's error-proofing system could register a completed assembly even with the ball joint only partially inserted. For vehicles built on or after that date, some units flagged for in-plant repair were shipped before the repair was completed, according to the recall report.
