Ford Motor Company (Ford) have discovered a defect affecting certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.

The following vehicle models are affected by this recall:

In January 2022, an investigation was opened into certain 2021 Lincoln Aviator and Nautilus vehicles equipped with 2.7L and 3.0L Nano EcoBoost engines after 22 instances of engine failure were reported within three months of service. The issue involved left-hand engine intake valve fractures, which led to catastrophic engine damage and Loss of Motive Power (LOMP). A tear down analysis confirmed intake valve fractures in 251 engines from warranty repairs.

Ford traced the problem to intake valves exceeding the hardness specification due to faulty grinding processes by the supplier. The intake valve material was changed for vehicles produced after October 31, 2021, to improve robustness.

On May 5, 2022, Ford opened an internal investigation into early intake valve fractures, and on May 27, 2022, the National Highway Traffic Safety Administration (NHTSA) began its own investigation after receiving reports from Ford Bronco owners. NHTSA expanded the scope of the investigation in July 2022.

On September 29, 2023, NHTSA expanded their investigation to include all 2021 and 2022 Ford/Lincoln models with 2.7L and 3.0L engines. As of August 9, 2024, Ford reported 811 global warranty claims and 267 field reports related to fractured intake valves. On August 16, 2024, Ford’s Field Review Committee approved a field action to address the issue.

Dealers will perform an engine cycle test and replace the engine as necessary. Owner notification letters are expected to be mailed October 7, 2024. Ford’s number for this recall is 24S55 and the NHTSA campaign number is 24V-635.