The National Highway Traffic Safety Administration (NHTSA) has officially closed its investigation into potential engine failures in certain Ford vehicles. This decision comes after a 2.5-year probe and Ford’s subsequent actions to address the issue, including engine replacements and extended warranties for affected models.
The NHTSA documents, released on Monday, detail that the investigation, which began in May 2022, focused on fractured intake valves within specific Ford engines. These faulty valves were identified in certain 2.7-liter and 3-liter turbocharged engines, leading to concerns about catastrophic engine failure.
The investigation encompassed over 411,000 vehicles from the 2021 and 2022 model years. Notable models included in the Ford Engine Recall investigation were the Ford F-150, Bronco, Edge, and Explorer, as well as the Lincoln Aviator and Nautilus. The core issue was the potential for intake valves to fracture, detach, and fall into the engine cylinder, striking the piston and causing significant engine damage.
Faulty Intake Valves: The Root Cause of Ford Engine Issues
Forensic analysis of the fractured intake valves revealed a critical manufacturing defect. A parts supplier’s manufacturing process caused excessively high temperatures during valve production. This elevated temperature made the valves brittle and susceptible to fracture under normal engine operating conditions.
NHTSA’s analysis of failure reports pinpointed the production timeframe of these defective valves to between May and October 2021. Ford argued that while some valves produced during this period were faulty, the vast majority of failures occurred early in the vehicle’s life, typically before reaching 20,000 miles.
Ford’s Response: Recalls and Warranty Extensions
Earlier this year, Ford initiated a Ford engine recall, bringing in approximately 91,000 vehicles equipped with valves manufactured during the suspect period. As part of this recall, these vehicles are undergoing testing, and engine replacements are being performed where necessary.
Furthermore, Ford has extended the warranty coverage for vehicles containing valves produced within the identified timeframe. This extended warranty now covers engine valve issues for up to 10 years or 150,000 miles, providing owners with added peace of mind.
Investigation Data and Conclusion
Throughout the NHTSA investigation, the agency documented 396 customer complaints, 825 warranty claims, and 936 engine replacements related to this issue. Despite the significant number of reported failures, it is important to note that no crashes or injuries have been attributed to these Ford engine recall concerns.
NHTSA’s statistical analysis and review of failure reports aligned with Ford’s assessment, indicating that valve failures predominantly occur at lower mileage and that a substantial portion of vehicles with faulty valves had already experienced failures. Based on Ford’s actions and the data analysis, NHTSA concluded that Ford had adequately addressed the safety risk, leading to the closure of the investigation.
