The U.S. government's auto safety regulator has concluded a 2 1/2-year investigation into Ford engine failures after the company took remedial actions to address the issue. The National Highway Traffic Safety Administration revealed that the problem stemmed from intake valves that could fracture within certain 2.7-liter and 3-liter turbocharged engines.
The investigation, which began in May of 2022, encompassed over 411,000 vehicles from the 2021 and 2022 model years, including popular models such as the Ford F-150 Bronco, Edge, and Explorer, as well as the Lincoln Aviator and Nautilus.
The root cause of the engine failures was identified as intake valves fracturing, subsequently dropping into the cylinder and impacting the piston. A forensic analysis of the fractured valves indicated that excessive temperatures during the manufacturing process rendered them brittle and prone to fracturing under normal engine operation.
The faulty valves were predominantly produced between May and October of 2021, with Ford asserting that not all valves manufactured during this period were defective. The majority of failures occurred before the affected vehicles had been driven 20,000 miles.
In response to the issue, Ford initiated a recall earlier this year for approximately 91,000 vehicles equipped with valves produced during the suspect timeframe. These vehicles will undergo testing, and if necessary, receive a new engine. Additionally, the company extended the warranty on vehicles featuring valves from the identified period to 10 years or 150,000 miles.
Throughout the investigation, the regulatory agency documented 396 customer complaints, 825 warranty claims, and 936 engine replacements. Fortunately, there were no reported accidents or injuries resulting from the engine failures.
