- Ford has issued a recall for 90,736 vehicles due to potential severe engine failures.
- In specific 2.7-liter and 3.0-liter EcoBoost V-6 engines, malfunctioning intake valves could fracture.
- This recall impacts the 2021-2022 models of the F-150, Bronco, Explorer, Edge, Lincoln Nautilus, and Lincoln Aviator.
Ford has faced significant recall challenges in recent years, and 2024 seems poised to be particularly problematic. This recall, which marks the 46th for Ford this year, involves 90,736 vehicles equipped with 2.7-liter or 3.0-liter EcoBoost V-6 engines. There is a risk that intake valves in these engines may break and fall into the combustion chamber, leading to catastrophic engine failure.
These engine types are used across several Ford models. The recall specifically includes the F-150, Bronco, Edge, and Explorer, as well as the Lincoln Nautilus and Aviator, all from the 2021 and 2022 production years. This issue with valve failure is not a rare occurrence; the recall documents available on the National Highway Traffic Safety Administration (NHTSA) website cite 328 customer complaints, 487 warranty claims, and 809 engine replacements.
An investigation revealed that the faulty valves were made from an alloy known as Silchrome Lite, which can become brittle if subjected to excessive heat during machining. Recall documents state that Ford transitioned to a different alloy in October 2021 that is “less prone to overheating during machining.” Although Ford suspects that many of the valves that could potentially fail have already done so, the automaker is still proceeding with this significant recall.
However, there are questions regarding the proposed solution, as there is no indication that the potentially defective valves will be replaced. According to the recall notice, Ford dealers will evaluate the affected vehicles to determine their cumulative number of engine cycles. For vehicles that do not meet the required engine cycle threshold, dealers will increase high revolutions per minute (rpm) engine cycles following a service procedure. Engines will be replaced in vehicles that do not pass the engine cycle assessment.
We have reached out to Ford for clarification on the remedy and expect to have more information soon. A spokesman for the company indicated that in addition to the immediate recall, a special customer satisfaction program is available for affected vehicle owners. If an intake valve failure occurs within 10 years or 150,000 miles, owners may qualify for a one-time engine replacement.
The spokesperson also issued this statement:
“Our objective is to prevent quality issues from arising in the first instance. When they do occur, our priority is to react promptly with a recall or service action to minimize inconvenience for our customers. We take pride in our launch quality reaching top tier standards, and we are seeing improvements in our long-term quality.”
This recall might sound familiar; it originated from a 2022 NHTSA investigation into engine failures in the Ford Bronco. The recall includes 15,835 Broncos equipped with the 2.7L and 3.0L engines, with the F-150 leading the count at 47,719 vehicles affected.
Ford’s Recall Challenges:
Dealers will start notifying customers about the recall on September 30, with individual owner notifications set to follow on October 7.
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