The U.S. National Highway Traffic Safety Administration (NHTSA) has concluded a 2.5-year investigation into engine failures in certain Ford models after the automaker replaced engines and extended warranties on affected vehicles.
The issue, which involved over 411,000 vehicles from the 2021 and 2022 model years, stemmed from intake valves in some 2.7-liter and 3-liter turbocharged engines that fractured during use.
The probe into Ford engine failures covered several models, including the Ford F-150, Bronco, Edge, Explorer, and Lincoln Aviator and Nautilus. NHTSA’s analysis found that the problem originated with valves made by a supplier from May to October 2021. An elevated temperature during production made the valves brittle, increasing their likelihood of fracturing, dropping into the cylinder, and damaging the engine.
Ford previously recalled around 91,000 vehicles equipped with suspect valves, offering testing and engine replacements if needed. The automaker also extended the warranty on affected vehicles to 10 years or 150,000 miles. NHTSA reported 396 complaints, 825 warranty claims, and 936 engine replacements but found no related crashes or injuries.
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