Ford Recalls Over 90,000 Vehicles Due To Risk of Engine Failure, Power Loss

Federal highway safety officials have announced a recall impacting six different Ford models equipped with certain NanoBoost engines, which could unexpectedly lose power and increase the risk of a crash.

The U.S. National Highway Traffic Safety Administration (NHTSA) announced the Ford engine failure recall on August 30, warning that certain vehicles from the 2021 and 2022 model years may contain faulty intake valves, which may lead to engine damage and a loss of motive power, including:

• 2021-2022 Ford Bronco with a 2.7L or 3.0L NanoBoost engine
• 2021-2022 Ford Edge with a 2.7L NanoBoost engine
• 2021-2022 Ford Explorer with a 3.0L NanoBoost engine
• 2021-2022 Ford F-150 with a 2.7L NanoBoost engine
• 2021-2022 Lincoln Aviator with a 3.0L NanoBoost engine
• 2021-2022 Lincoln Nautilus with a 2.7L NanoBoost engine

While Ford says that it is not aware of any accidents or injuries related to the recall, the notice indicates that a growing number of warranty claims have been submitted by customers in recent months.

The automaker first became aware of the issue in January 2022, when an international investigation discovered 22 instances of engine failure in 2021 Lincoln Aviator and Nautilus vehicles equipped with 2.7L and 3.0L Nano EcoBoost gasoline engines, all occurring within the first three months of service.

The investigation revealed the engine intake valves fractured and fell into the combustion chamber of the engine, causing severe engine damage that resulted in a Loss of Motive Power (LOMP).

Further analysis found the root cause of the failures are engine intake valves that exceed the designed hardness specifications, making them brittle and more likely to fracture. Ford Motor Company determined this occurred because the supplier’s grinding processes did not meet control specifications, which failed to account for the sensitivity of the intake valve material, resulting in potential grinding burn and over-specification hardness at the third keeper groove.

While collecting parts for analysis, Ford identified 251 engine intake valve fractures from warranty repairs on 2021 Ford and Lincoln vehicles equipped with 2.7L and 3.0L Nano EcoBoost gasoline engines. In September 2023, the NHTSA expanded the investigation to include all 2021 and 2022 Ford and Lincoln vehicles equipped with the same engine. Ford then noted a higher than average level of repairs for vehicles produced between May 1 and October 31, 2021.

Ford documented that there were 267 field reports submitted between October 2020 and October 2023, and 223 customer reports submitted between March 2021 and August 2023. As of August 9, 2024, Ford has become aware of 811 global warranty claims confirmed or suspected to be related to fractured intake valves with report dates ranging from February 13, 2021 to June 3, 2024.

Ford estimates that 90,736 vehicles are at risk of a faulty intake valve, warning owners to watch for an engine malfunction indicator lamp.  Vehicles may also start “running rough” before losing motive power.

Owners should begin receiving notification letters in October 2024, with instructions on how to schedule a free repair at their local dealer. Dealers will be instructed to inspect the cumulative number of engine cycles and replace engines, free of charge, if the vehicles do not meet the required engine cycle accumulation.

Any vehicle owners who have already had this remedy performed at their own expense prior to the recall notification may be eligible for reimbursement, in accordance with the recall reimbursement plan.

Ford’s number for this recall is 24S55. Customers with additional questions may contact Ford customer service at 1-866-436-7332, or Ford Motor Company’s contact for this recall, Dusty Gardner, who may be reached by email at dusty.gardner@dot.gov. 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.