Ford Motor Company have identified a critical issue in certain 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles equipped with the 3.5L GTDI engine. A misaligned engine cup plug has been found to potentially result in a rapid oil leak, posing serious safety risks.
The Problem: Misaligned Engine Cup Plug
The defect stems from a misalignment of the hydraulic press used to insert engine cup plugs into the cylinder head bore during assembly. This misalignment, approximately 1.5 mm off center, distorts the cup plug, reducing its retention within the bore. This defect may result in:
- Rapid Oil Leak: A misaligned plug can cause sudden, large-volume oil loss.
- Increased Fire Risk: Oil leaks in the presence of hot engine or exhaust components may lead to a fire.
- Loss of Motive Power: A sudden loss of oil can result in reduced engine performance or a complete loss of motive power, increasing the risk of a crash.
Warning Signs for Customers
Drivers of affected vehicles may notice several warning signs, including:
- Low Oil Pressure Warning: A warning light on the instrument cluster.
- Burning Smell or Smoke: White smoke or a burning odor from the engine compartment.
- Oil Leak or Engine Noise: Visible oil leakage or unusual noises from the engine.
Discovery and Investigation
The issue first came to Ford’s attention in October 2024 during a vehicle evaluation at the Kansas City Assembly Plant. A 2024 F-150 equipped with the 3.5L GTDI engine experienced a significant oil leak caused by the expulsion of a 13mm engine cup plug on the exhaust side.
Ford’s Critical Concern Review Group (CCRG) conducted an investigation and tear down analysis. They found no damage to the cylinder head bore but discovered that the cup plug was off center. The misalignment was traced back to maintenance work on the cylinder head assembly line at the Cleveland Engine Plant between September 9, 2024, and September 16, 2024. Other stations were confirmed to have proper alignment.
Field Action and Customer Notification
As of October 30, 2024, Ford has not received any warranty claims or field reports from customers regarding this issue. However, the company is taking measures to ensure customer safety:
- Field Action Approval: Ford’s Field Review Committee approved the recall on November 1, 2024.
- Dealer Inspections and Repairs: Dealers will inspect the cup plug alignment and replace any misaligned plugs.
- Customer Notifications: Owner notification letters are scheduled to be mailed by December 2, 2024.
Recall Details
- Ford Recall Number: 24S70
- NHTSA Campaign Number: 24V-851
Next Steps for Vehicle Owners
Ford advises owners of the affected 2024-2025 F-150, 2024 Expedition, and 2024 Lincoln Navigator vehicles to monitor for any signs of the defect and to schedule an inspection with their dealer once notified. This precautionary recall aims to address the issue and ensure vehicle safety and reliability.
