2024 BS water pump leak

[HankSmith]

New member here, the 3cyl Outer Banks is driven by my wife. It was her idea to purchase it, as I am partial to certain brands that will go unnamed here. But I will say they are the brands with the reputation to go well past 100k miles before anything breaks and I know this to be true from experience.
The Bronco has less than 10k miles and the water pump leaks coolant. The appointment to replace it is this week. In researching the issue, I found that this is common and there may be a recall soon. Also, some owners have had the pump changed repeatedly as it is replaced with the same faulty design. My question is whether anyone knows if the recall will be a redesigned one that will last longer?

Ford needs to get their act together with respect to quality. In my circle of friends I am aware of several examples of serious issues across the model lineup that start early in the vehicles' lifespans. That doesn't make me want to keep the BS past the warranty and the next car will come from a different manufacturer.

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[Dude]

There’s only rumors so far of a Recall for the leaking water pump issue on 1.5L Bronco Sport Models

I know of 2 water pump part #s and both leak - affecting at least some ‘21-‘24 Bronco Sports

See this post:
TSB 25-2063 might be the latest (check with your dealership)

https://www.broncosportforum.com/forum/threads/low-speed-pop-in-drive-reverse.13651/post-236665

“If it’s really the case that engine casting sand is the actual root cause (which I’m skeptical), getting out all casting sand isn’t easy

The tech likely will share with you what is believed by the tech to be the root cause - assuming the tech has performed the procedure enough times on vehicles to form an opinion”

TSB 25-2063:
https://static.nhtsa.gov/odi/tsbs/2025/MC-11014866-0001.pdf

 

[HankSmith]

There’s only rumors so far of a Recall for the leaking water pump issue on 1.5L Bronco Sport Models

I know of 2 water pump part #s and both leak - affecting at least some ‘21-‘24 Bronco Sports

See this post:
TSB 25-2063 might be the latest (check with your dealership)

https://www.broncosportforum.com/forum/threads/low-speed-pop-in-drive-reverse.13651/post-236665

“If it’s really the case that engine casting sand is the actual root cause (which I’m skeptical), getting out all casting sand isn’t easy

The tech likely will share with you what is believed by the tech to be the root cause - assuming the tech has performed the procedure enough times on vehicles to form an opinion”

TSB 25-2063:
https://static.nhtsa.gov/odi/tsbs/2025/MC-11014866-0001.pdf

Thanks for the reply. I'll check that out. This car sees a lot of short stop and go trips. I'm far from an egnineer but it's my understanding that certain components have to be beefed up for the start / stop feature, such as the starter. Maybe the water pump can't take all that on / off stuff? It'd be interesting to know if the owners who have had no issues with a coolant leak drive mostly highway.

 

[Dude]

I'm far from an egnineer but it's my understanding that certain components have to be beefed up for the start / stop feature, such as the starter. Maybe the water pump can't take all that on / off stuff?

If you are interested you could look on this forum - lots of discussion and videos about auto stop/start and its impact on various components. Bottom line is the starter is designed for the auto stop/start system so expecting the starter to typically outlast the vehicle. The 1.5L water pump failures haven’t been implicated with the auto stop/start system as far as I know.

There are various schools of thought on root cause of 1.5L water pump failures as reported by a few Ford mechanics and or Ford itself:

1. Casting sand (in the coolant passages) left over from the engine block or other engine component manufacturing - this is what Ford documents in various SSMs and TSBs

2. Poor design and or manufacturing of both water pump versions (several Ford mechanics have stated that)

3. Some owners believe it is the “constant pressure of the self-tensioning belt system”

Jury is still out.

 

[cprcubed]

FWIW, my 2022 BB water pump leaks and I haven't used the AS/S system since it was new (it's been disabled with an AS/S Eliminator). Cheers!

 

[R W NORRIS New Mexico]

36K on my 22 BS Big Bend when the pump started to leak and had to be replaced. Now for the reason, if it were "sand" I would expect other internal pumps to fail as well as the Valves, Rings, Lifters and ect. Next sand would "scar" the Cylinder walls and the engine would seep oil and smoke in short order. Hyundai had that problem a few years back and had to replace a number of engines and it actually was verified sand from the casting cleaning procedure. I have my own ideas about it, and I AM NOT qualified to have ideas. LOL I think that the constant pressure of the self-tensioning belt system may be part of it. If you constantly pull up on a pulley the bearings will wear against the seal, which is what my old pump demonstrated when removed. So that and $6.00 will buy you a cup of coffee today and I gave you that for free. lol The replacement cost at Ford for the water pump is $1100+ and that includes flushing the system and new coolant, however, the cost at local shops is quoted to me at $350. Something to look forward too.

 

[thomasm23]

36K on my 22 BS Big Bend when the pump started to leak and had to be replaced. Now for the reason, if it were "sand" I would expect other internal pumps to fail as well as the Valves, Rings, Lifters and ect. Next sand would "scar" the Cylinder walls and the engine would seep oil and smoke in short order. Hyundai had that problem a few years back and had to replace a number of engines and it actually was verified sand from the casting cleaning procedure. I have my own ideas about it, and I AM NOT qualified to have ideas. LOL I think that the constant pressure of the self-tensioning belt system may be part of it. If you constantly pull up on a pulley the bearings will wear against the seal, which is what my old pump demonstrated when removed. So that and $6.00 will buy you a cup of coffee today and I gave you that for free. lol The replacement cost at Ford for the water pump is $1100+ and that includes flushing the system and new coolant, however, the cost at local shops is quoted to me at $350. Something to look forward too.

The residual sand is in the coolant passages. This will only effect the cooling system components.

 

[R W NORRIS New Mexico]

I agree with you Tom. Just a thought that if the coolant passages had sand, then perhaps the "engine block bath" was not good enough for all "cracks and crevesses" as is said, but you are correct.

 

[Bucko]

36K on my 22 BS Big Bend when the pump started to leak and had to be replaced. Now for the reason, if it were "sand" I would expect other internal pumps to fail as well as the Valves, Rings, Lifters and ect. Next sand would "scar" the Cylinder walls and the engine would seep oil and smoke in short order. Hyundai had that problem a few years back and had to replace a number of engines and it actually was verified sand from the casting cleaning procedure. I have my own ideas about it, and I AM NOT qualified to have ideas. LOL I think that the constant pressure of the self-tensioning belt system may be part of it. If you constantly pull up on a pulley the bearings will wear against the seal, which is what my old pump demonstrated when removed. So that and $6.00 will buy you a cup of coffee today and I gave you that for free. lol The replacement cost at Ford for the water pump is $1100+ and that includes flushing the system and new coolant, however, the cost at local shops is quoted to me at $350. Something to look forward too.

If you are getting casting sand from the cooling system into your cylinder walls and valves, then you have other serious issues to be concerned with. This casting sand that is being referenced is only within the cooling system. If coolant were to get into the cylinder combustion cambers, it would be a head gasket failure or cracked block (water jacket to cylinder bore).

 

[Dude]

https://www.broncosportforum.com/forum/threads/is-your-1-5l-engine-water-pump-leaking-and-you-are-out-of-warranty-who-you-gonna-call.15304/

 

[HankSmith]

Update: The water pump and serpentine belt were replaced under warranty. The last digit of the part number on the pump is a "B" not an "A" , curious to know if that is a new improved design or similar enough to fail early, too.
Or : Have any known repeat failures happened with the "B" unit?

 

[Dude]

Update: The water pump and serpentine belt were replaced under warranty. The last digit of the part number on the pump is a "B" not an "A" , curious to know if that is a new improved design or similar enough to fail early, too.
Or : Have any known repeat failures happened with the "B" unit?

Both 1.5L water pump part numbers, A and B are known to fail. Owners have even posted their B water pump failed, replaced with another B and that also failed

See post #2 here
https://www.broncosportforum.com/forum/threads/is-your-1-5l-engine-water-pump-leaking-and-you-are-out-of-warranty-who-you-gonna-call.15304/

 

[HankSmith]

Both 1.5L water pump part numbers, A and B are known to fail. Owners have even posted their B water pump failed, replaced with another B and that also failed

See post #2 here
https://www.broncosportforum.com/forum/threads/is-your-1-5l-engine-water-pump-leaking-and-you-are-out-of-warranty-who-you-gonna-call.15304/

Thank you.
That answers the question if we will keep the BS for longer than the warranty: No.

 

[Quashish]

FWIW, my 2022 BB water pump leaks and I haven't used the AS/S system since it was new (it's been disabled with an AS/S Eliminator). Cheers!

same with our 21 big bend. Never had ASS enabled and pump failed at around 20k miles.

 

[BSBB4Les]

FWIW, my 2022 BB water pump leaks and I haven't used the AS/S system since it was new (it's been disabled with an AS/S Eliminator). Cheers!

Same for me and my '22 BB at 24,300 mi. I traded her for a 2024 BB 4 months later.

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