On August 23, 2024, Ford announced a recall effecting 90,736 vehicles due to issues with engine intake valve steams that could, according to the NHTSA (National Highway Traffic Safety Administration), “break while driving, which can result in engine failure and a loss of drive power.”
Effected vehicles include 2021 and 2022 model year Ford Bronco, F-150, Edge, and Explorer as well as Lincoln Nautilus and Aviator, specifically those equipped with either the 2.7L or 3.0L Nano EcoBoost V6 engine. Ford’s recall notice specifies the problem as involving faulty intake valve stems whose material can become brittle under stress, break, and fall into the cylinder causing engine failure and a loss of motive power. According to the recall notice, Ford changed the valves’ production process as of Oct. 31st, 2021, to address the issue.
Ford says letters to affected owners will start going out Oct. 7th, 2024. Ford will perform an engine cycle test on affected vehicles and any engine that fails that test will be replaced at no expense to the owner. Additionally, those owners who have already paid for such repairs will be eligible for reimbursement.
Owners are encouraged to visit the NHTSA website here and enter their vehicle’s VIN number to verify whether their vehicle is affected by the recall.
This is not the first time Ford has had problems with their EcoBoost engines. Early applications of Ford’s EcoBoost turbocharging in engines like the 1.0L “Fox” three-cylinder as well as the 1.6L “Sigma” and 2.0L GDI four-cylinder engines led to recalls and subsequent redesigns.
Unfortunately for Ford, this also is not the first time the 2.7L and 3.0L Nano EcoBoost V6s have been recalled for intake valve problems. A nearly identical recall was initiated in 2015 when a new alloy was blamed for valve steam breakage.
As of July 2024, Ford sat atop an ignominious list with the most recalls of any major automotive manufacturer this year with 31 recalls of over 3.6 million vehicles. Tesla was not far behind with eight recalls affecting over 2.6 million vehicles.