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Ford and Lincoln are recalling nearly 91,000 models with the 2.7- and 3.0-liter EcoBoost engines that may fail.
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The recall affects 2021 to 2022 models with those engines, including the Ford F-150, Bronco, Explorer, and Edge; the Lincoln Aviator and Nautilus are affected too.
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Ford says the issue involves faulty engine intake valves that may fracture and fall into the combustion chamber, causing catastrophic failure.
Thousands of Ford EcoBoost engines are at risk of failure, which has caused the automaker to issue a recall. The issue involves 90,736 models, including some Lincolns, equipped with the turbocharged 2.7-liter four-cylinder and twin-turbo 3.0-liter V-6 that may have faulty engine intake valves.
Ford filed documents on August 23, 2024, with the National Highway Traffic Safety Administration (NHTSA). The affected vehicles are 2021–2022 models. The list of Fords includes the Bronco, the F-150, the Explorer, and the Edge. The list of Lincolns is limited to the Aviator and Nautilus. The F-150 has by far the biggest population that’s potentially affected, with 47,719 involved in the recall. The Bronco and Explorer are next with 15,835 and 14,262 models, respectively. Meanwhile, Ford is recalling 2366 Edges, 7199 Lincoln Aviators, and 3355 Lincoln Nautilus models.
According to the chronology documents it submitted to NHTSA, Ford said an investigation began back in January 2022 following 22 instances of engine failure after three months or less involving Lincoln Aviator and Nautilus models equipped with the 2.7- or 3.0-liter EcoBoost engines. The investigation found that the catastrophic damage was caused by engine intake valves that fractured and fell into the combustion chamber. It was revealed that the material the valve supplier used was not up to specification, but the valve’s robustness was improved starting on models built after October 31, 2021.
The following year, Ford investigated intake-valve fractures on 2021 Bronco models and found 251 instances of the issue during warranty repairs. NHTSA then opened a “Defect Petition” in May 2022 as a result of increasing complaints from Bronco customers. Ford responded to NTHSA in January 2024, noting that there was a “higher than ambient level of repairs observed for vehicles produced between May 1 and October 31, 2021.”
Ford says as of Aug. 9, 2024, it is aware of 811 warranty claims associated with fractured intake valves. The automaker has since approved a remedy for affected vehicles, which involves dealers inspecting each model by determining their cumulative number of engine cycles. Ford will replace engines that don’t pass that inspection. The company also said it has provided a reimbursement plan for owners who have already paid for the repair out of pocket. Dealers will be notified on September 30, and letters will be sent to owners starting on October 7.
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