Ford issues recall for more than 90,000 vehicles due to Ecoboost engine malfunctions
Ford Motor Company has announced a recall of nearly 4 million SUVs from model years 2021 and 2022, including the Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Aviator, equipped with either 2.7L or 3.0L EcoBoost engines.
The recall comes in response to numerous complaints from owners of the 2021 Ford Bronco regarding severe engine damage. The National Highway Traffic Safety Administration (NHTSA) launched a defect petition on May 27, 2022, following these complaints.
An investigation by Ford's Critical Concern Review Group (CCRG) revealed that the supplier's grinding processes for the intake valves were not within control specifications, resulting in insufficient hardness of the metal. This makes the valves brittle and more susceptible to cracking.
The NHTSA opened a more thorough engineering analysis in September 2023, which expanded to other 2021 and 2022 Ford and Lincoln vehicles equipped with the same 2.7L and 3.0L EcoBoost engines. The estimated number of Ford vehicles with the engine defect could be as high as 708,837.
Ford is aware of 267 field reports of engine failures from October 6, 2020, to October 18, 2023, and 223 customer reports dated between March 31, 2021, and August 29, 2023. After a teardown of the failed engines from vehicles being serviced under warranty, Ford engineers discovered intake valve fractures on 251 of them.
In these instances, the fractured intake valves fell into the combustion chamber, leading to catastrophic engine damage. As part of the recall, dealers will inspect the vehicles to determine if they meet Ford's cycle threshold test. Engines that do not meet the test will be replaced at no cost.
The intake valves were manufactured by Nebraska-based supplier Eaton Corp. The supplier of the damaged intake valves for the affected Ford and Lincoln vehicles has not been explicitly identified in the provided search results.
It's worth noting that Ford has issued 46 separate recalls since January 2024, the most out of any other automaker in that year. Owners that have already paid to have their engines repaired may be eligible for reimbursement.
The recall notification letters are expected to be sent to Ford dealers on September 30, and owner notifications are expected to be sent between October 7-11. The intake valve material was changed for vehicles produced after October 31, 2021, increasing the valve's hardness and durability.
The NHTSA's Office of Defects Investigation identified 26 questionnaires related to the issue, according to the report. The recall affects a significant number of Ford and Lincoln vehicles, and it's crucial for owners to stay informed and follow the recall instructions.
