The U.S. National Highway Traffic Safety Administration (NHTSA) has officially closed a two-and-a-half-year investigation into Ford engine failure. The decision comes after Ford implemented measures to address the issue, including engine replacements and an extended warranty for affected vehicles. The investigation, which began in May 2022, examined over 411,000 Ford models from the 2021 and 2022 model years. Affected models include the popular Ford F-150, Bronco, Edge, and Explorer, as well as the Lincoln Aviator and Nautilus.
NHTSA documents, released on Monday, reveal that the investigation traced the problem to fractured intake valves in Ford’s 2.7-liter and 3-liter turbocharged engines. These fractured valves led to serious Ford engine failures, as they could drop into the cylinder and strike the piston, resulting in significant damage.
Cause and Extent of the Engine Failures
Ford engine failure issue was identified as stemming from intake valves that became brittle during the manufacturing process. According to NHTSA’s findings, the problem occurred when the parts supplier’s production process caused the intake valves’ temperature to exceed safe levels. This high heat exposure made the valves more susceptible to fractures under normal engine operation. NHTSA’s analysis of the failure reports concluded that the problematic valves were manufactured between May and October 2021. Ford, however, maintained that not all intake valves produced during this period were defective and noted that most failures occurred before the vehicles reached 20,000 miles.
NHTSA’s statistical analysis supported Ford’s assessment, indicating that the faulty intake valves predominantly failed at low mileage. The agency believes that the majority of affected vehicles have already encountered the issue, allowing Ford’s remedial actions to mitigate further risks effectively.
Ford’s Response and NHTSA Findings
Earlier in 2023, Ford issued a recall affecting approximately 91,000 vehicles with intake valves manufactured during the identified period. Under this recall, affected vehicles will be tested, and engines will be replaced if necessary. In addition to the recall, Ford extended the warranty on vehicles with these intake valves to cover a span of 10 years or 150,000 miles. According to NHTSA, the investigation uncovered 396 customer complaints, 825 warranty claims, and 936 engine replacements, though no accidents or injuries related to the issue were reported.
By concluding the investigation, NHTSA has signaled confidence in Ford’s corrective actions and warranty extensions to support affected consumers.
