In a year already marked by a series of recalls, Ford has announced its 46th recall of 2024, impacting over 90,000 vehicles. The latest recall addresses a potentially devastating issue involving the intake valves in certain 2.7-liter and 3.0-liter EcoBoost V-6 engines. These valves, which can break and cause catastrophic engine failure, are found in popular models like the 2021-2022 Ford F-150, Bronco, Explorer, Edge, Lincoln Nautilus, and Lincoln Aviator.
The recall affects 90,736 vehicles equipped with the 2.7-liter or 3.0-liter EcoBoost V-6 engines. These engines are known for their performance and efficiency, but they’ve now become the focus of concern due to the potential for intake valve breakage. If these valves break, they can drop into the combustion chamber, leading to severe engine damage and, in many cases, total engine failure.
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This issue isn’t just theoretical—Ford’s recall documents, posted on the National Highway Traffic Safety Administration (NHTSA) website, reveal that there have been 328 customer complaints, 487 warranty claims, and a staggering 809 engine replacements linked to this defect. The problem is traced back to a specific alloy, Silchrome Lite, used in the manufacturing of these valves. This alloy can become brittle if overheated during machining, making the valves prone to breakage.
The recall encompasses a wide range of Ford and Lincoln vehicles, all from the 2021 and 2022 model years:
Ford’s approach to resolving this issue has raised some eyebrows. Instead of a straightforward replacement of the faulty valves, Ford’s recall strategy involves inspecting the vehicles to assess the “cumulative number of engine cycles.” Vehicles that do not meet a certain threshold will undergo a service procedure that accumulates high revolutions per minute (rpm) engine cycles. If a vehicle fails this test, only then will the engine be replaced.
This approach has left many questioning its effectiveness and the logic behind not replacing all potentially defective valves. Ford has stated that they believe most of the valves that were prone to failure have already done so, but they are still proceeding with the large-scale recall as a precaution.
This isn’t the first time Ford has faced issues with these engines. In 2022, an NHTSA investigation into engine failures in the Ford Bronco prompted the inclusion of 15,835 Broncos in this latest recall. The 2.7L and 3.0L engines in these vehicles have now been flagged again, highlighting ongoing concerns with the engine’s durability and manufacturing processes.
As Ford navigates yet another recall in 2024, the focus on engine reliability and manufacturing processes is more critical than ever. For owners of affected vehicles, it’s essential to stay informed and act promptly to prevent potential engine failure. As this situation unfolds, it serves as a stark reminder of the importance of quality control in automotive manufacturing, especially in components as vital as the engine.
