Various Ford and Lincoln Recalls for Sudden Engine Failures

Ford Motor Company (NYSE: F) is recalling  2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a sudden loss of drive power.

Based on an analysis of returned fractured valves from failed engines, Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after 31 October 2021. The new material increased the valve’s robustness to keeper groove grinding processes outside of control specifications.

Dealers will perform an engine cycle test and replace the engine as necessary, free of charge. Owner notification letters are expected to be mailed October 7, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 24S55. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov about NHTSA recall 24V635.

Chronology

• On 25 January 2022, Global CCRG  (Critical Concern Review Group) opened an investigation into 2021 Model Year (MY) Lincoln Aviator and Nautilus vehicles equipped with 2.7L and 3.0L Nano EcoBoost gasoline engines after an international investigation discovered twenty-two (22) instances of engine failure at three (3) months in service or less. A review of failed engines revealed that the engine intake valves fractured and fell into the combustion chamber of the engine causing catastrophic engine damage leading to a Loss of Motive Power (LOMP). Based on an analysis of returned fractured valves from failed engines, Ford identified that the potential root cause of the failures was engine intake valve failure due to valves that exceeded the designed specification for hardness, were brittle, and more likely to fracture. Ford determined that this was due to the supplier’s grinding processes and the sensitivity of the intake valve material to grinding processes that were not within control specifications. The intake valve material was changed for vehicles produced after 31 October 2021. The new material increased the valve’s robustness to keeper groove grinding processes outside of control specifications.
• On 5 May 2022, Ford’s North America (NA) CCRG opened an investigation regarding early time in-service left-hand engine intake valve fractures on 2021 MY Ford and Lincoln vehicles equipped with 2.7L and 3.0L Nano EcoBoost gasoline engines. Teardown analysis of returned failed engines confirmed intake valve fracture on two-hundred fifty-one (251) engines from warranty repairs.
• On 27 May  2022, the National Highway Traffic Safety Administration (NHTSA) opened Defect Petition 22-001 in response to an increasing trend of Vehicle Owner Questionnaires (VOQs) submitted by 2021 MY Ford Bronco customers alleging Loss of Motive Power as a result of catastrophic engine damage.
• On 22 July 2022, NHTSA opened Preliminary Evaluation (PE) 22-007 to continue its investigation into 2021 MY Ford Bronco customer allegations of LOMP. Ford’s response was provided to NHTSA on 28 September 2022.
• On 29 September 29, 2023, NHTSA opened Engineering Analysis (EA) 23-002 and expanded the scope of its investigation to include all 2021 and 2022 MY Ford and Lincoln products that are equipped with the 2.7L and 3.0L Nano EcoBoost engines. Ford’s response was provided to NHTSA on 2 January 2024. Ford noted that there was a higher than ambient level of repairs observed for vehicles produced between 1 May and 31 October 2021.
• On 4 December 2023, NHTSA personnel visited Ford facilities to observe Ford’s engine teardown and laboratory analysis processes for evaluating fractured intake valves.
• Between February and August 2024, Ford has participated in several discussions related to fractured intake valves on Nano EcoBoost engines with NHTSA.
• As of August 09, 2024, Ford is aware of 811 global warranty claims confirmed or suspected to be related to fractured intake valves with report dates ranging from 13 February 2021 to 3 June 2024. Ford is aware of 267 field reports with report dates of 6 October 2020 to 8 October 2023. Ford is also aware of 223 customer reports with report dates of 31 March 2021 to 9 August 2023.
• On 16 August 16, 2024, Ford’s Field Review Committee reviewed the concern and approved a field action. Ford is not aware of any reports of accident or injury related to this safety defect.