Ford’s New Recall: 90k+ Vehicles Affected by Massive Engine Failure

Ford Recalls Over 90,000 Vehicles Due to Faulty Engines

Ford recently issued a significant recall affecting over 90,000 vehicles, including several popular models equipped with the EcoBoost engines. The recall stems from a critical issue with the engine intake valves, specifically in the 2.7-liter and 3.0-liter turbocharged V6 engines found in certain 2021–2022 models. The vehicles impacted by this recall include the Ford F-150, Bronco, Explorer, Edge, and two Lincoln models: the Aviator and Nautilus. This recall underscores the importance of engine reliability, particularly in performance-oriented engines like Ford’s EcoBoost line.

The Heart of the Problem: Faulty Intake Valves

The issue at the core of this massive recall is the engine intake valves, which are crucial components in managing airflow into the combustion chamber. Unfortunately, a material defect in the intake valves has been discovered, which could lead to them fracturing and falling into the combustion chamber. When this happens, the result is catastrophic engine damage, potentially leaving drivers stranded with a dead engine.

The specific engines affected are the 2.7-liter turbocharged V6 and the 3.0-liter twin-turbocharged V6, both of which are key components of Ford’s performance lineup. These engines are designed to deliver high power outputs while maintaining fuel efficiency—a hallmark of the EcoBoost brand. However, this recall highlights the fine line automakers walk between pushing the limits of performance and ensuring long-term durability.

Which Models Are Affected?

The recall affects a broad range of Ford and Lincoln models, with some of the most popular vehicles in Ford’s lineup being impacted. The breakdown of affected vehicles is as follows:

• Ford F-150: The F-150, Ford’s best-selling vehicle and a staple in the American automotive landscape, is the most affected, with 47,719 units involved in the recall.
• Ford Bronco: The Bronco, Ford’s rugged off-road icon, has 15,835 units affected.
• Ford Explorer: The Explorer, a popular SUV, has 14,262 models involved in the recall.
• Ford Edge: This midsize SUV has 2,366 units affected.
• Lincoln Aviator: Lincoln’s luxury SUV has 7,199 units involved in the recall.
• Lincoln Nautilus: The Nautilus, another luxury SUV from Lincoln, has 3,355 units affected.

This recall represents a significant portion of Ford’s production over the past couple of years, and the company is taking steps to address the issue head-on.

Timeline of the Issue: A Growing Concern

The problem with the intake valves first came to light in January 2022 when Ford began investigating reports of engine failures in the Lincoln Aviator and Nautilus models equipped with the affected engines. In these cases, the engines failed within just three months of operation, prompting Ford to delve deeper into the issue.

As the investigation progressed, Ford discovered that the intake valves in these engines were not meeting the required material specifications. The supplier responsible for the valves had used a material that was not up to Ford’s standards, leading to a higher-than-expected rate of valve fractures.

The situation escalated in 2023 when Ford began to receive more reports of engine failures, this time from owners of the 2021 Bronco. Warranty repairs revealed 251 instances of valve fractures, which further confirmed the severity of the problem.

In May 2022, the National Highway Traffic Safety Administration (NHTSA) opened a “Defect Petition” in response to the growing number of complaints from Bronco owners. Ford continued its investigation and by January 2024, the automaker acknowledged that vehicles produced between May 1 and October 31, 2021, exhibited a higher-than-normal rate of engine failures due to these defective valves.

The Impact on Ford’s Reputation

This recall is a significant blow to Ford’s reputation, particularly for its EcoBoost engines, which have been praised for their blend of performance and efficiency. The EcoBoost lineup is a critical part of Ford’s strategy to meet fuel economy standards while still delivering the kind of power that consumers expect from the brand.

However, the recall also highlights Ford’s commitment to addressing issues head-on. The company has been transparent about the problem and is taking swift action to remedy the situation. This recall, while damaging in the short term, could ultimately reinforce Ford’s reputation for customer safety and reliability if handled correctly.

The Remedy: What Ford Is Doing

To address the issue, Ford has developed a comprehensive plan to inspect and repair the affected vehicles. Dealers have been instructed to inspect each vehicle’s engine to determine the cumulative number of engine cycles—a key metric in assessing the engine’s wear and tear.

If an engine is found to be at risk of valve failure, Ford will replace the entire engine at no cost to the customer. This is a significant commitment, given the high cost of engine replacements, but it’s necessary to ensure the safety and reliability of the affected vehicles.

For customers who have already paid out of pocket for repairs related to this issue, Ford has established a reimbursement plan. This ensures that no customer is left bearing the financial burden of a problem that originated with the manufacturer.

Customer Communication and Next Steps

Ford is taking steps to ensure that all affected customers are informed about the recall and the steps they need to take. Dealers will be notified on September 30, and letters will be sent to vehicle owners starting on October 7. These letters will provide detailed instructions on how to have their vehicles inspected and repaired.

For many customers, this recall will be an inconvenience, but Ford is working to minimize the disruption. By taking swift action and providing clear communication, the automaker hopes to maintain customer trust during this challenging time.

The Bigger Picture: What This Means for the Industry

This recall serves as a reminder of the complexities involved in modern engine design and manufacturing. As automakers push the boundaries of what’s possible with internal combustion engines, the margin for error becomes increasingly thin. The materials used in engine components must meet exacting standards, and any deviation can lead to significant issues down the line.

For Ford, this recall is a costly lesson in the importance of supplier oversight and quality control. Ensuring that every component meets the required specifications is critical to maintaining the reliability and durability that customers expect from a brand like Ford.

The Future of EcoBoost Engines

Despite this setback, Ford remains committed to the EcoBoost engine lineup. These engines are a key part of Ford’s strategy to offer powerful, fuel-efficient vehicles across its lineup. The recall will undoubtedly lead to a re-evaluation of the materials and processes used in EcoBoost engines, with an eye toward preventing similar issues in the future.

Ford’s engineers are likely already working on ways to improve the robustness of these engines, ensuring that they can continue to deliver the performance that customers love while avoiding the pitfalls that led to this recall.

What Should Ford Owners Do?

If you own one of the affected vehicles, it’s important to take action as soon as possible. Even if you haven’t experienced any issues with your engine, having your vehicle inspected is the best way to ensure that it’s safe to drive.

Contact your local Ford dealer to schedule an inspection. If your vehicle needs repairs, Ford will cover the cost, so there’s no reason to delay. And if you’ve already had your engine repaired, be sure to take advantage of Ford’s reimbursement program.

Conclusion: A Bump in the Road, But Ford Will Rebound

This recall is undoubtedly a significant challenge for Ford, but it’s one that the automaker is tackling head-on. By acknowledging the issue, taking swift action, and providing customers with clear communication, Ford is demonstrating its commitment to safety and reliability.

While this recall may cause some short-term pain, it’s a necessary step in maintaining the trust of Ford’s loyal customer base. The lessons learned from this experience will likely lead to even better engines in the future, ensuring that the EcoBoost lineup continues to be a driving force in the automotive industry. Photo Credit – Ford