Ford Recalls Broncos, Explorers, F150s and other Vehicles Due to Engine Valve Defect

Ford has announced the recall of nearly 91,000 vehicles equipped with 2.7-liter and 3.0-liter EcoBoost engines. The issue impacts several popular models among off-roaders, overlanders, and outdoors enthusiasts, including the Ford F-150, Bronco, and Explorer.

The recall also affects the Ford Edge and two Lincoln models, the Aviator and Nautilus. It addresses a potentially catastrophic engine issue involving faulty intake valves.

The vehicles affected include 2021 to 2022 models, with Ford filing the recall documents on August 23, 2024, with the National Highway Traffic Safety Administration (NHTSA).

The problem stems from engine intake valves that may fracture, leading to the valves falling into the combustion chamber and potentially causing severe engine failure. While Ford estimates only 1% of the recalled vehicles could experience this defect, the number of vehicles at risk still amounts to thousands.

The F-150, in particular, has the highest number of affected vehicles, with 47,719 models being recalled. The Bronco, a favorite among off-road enthusiasts, has 15,835 affected models, while the Explorer, often modified for overlanding, has 14,262 vehicles under recall.

The defect was initially identified in January 2022, when Ford began investigating reports of engine failures in Lincoln Aviator and Nautilus models. The investigation revealed that the intake valves used in the engines were made with materials that did not meet the required specifications. As the issue persisted, Ford later expanded the investigation to include other models, including the Bronco, after noticing an uptick in warranty claims. By August 2024, Ford had logged over 800 warranty claims related to fractured intake valves.

Ford has developed a remedy for affected vehicles that involves inspecting engine cycles and replacing engines that show signs of valve issues. Owners will be notified by mail starting on October 7, 2024, and dealerships will be informed by the end of September.

Ford will cover the cost of engine replacements for impacted vehicles, and the company has also implemented a reimbursement plan for owners who have already paid for repairs.

While no accidents or injuries have been reported due to this defect, the recall has drawn attention due to the potential risk of engine failure while driving, which could lead to a sudden loss of power.

Overlanders and off-roaders relying on these vehicles for remote adventures should take note of the recall and ensure their vehicles are inspected promptly.

For those planning to take their F-150, Bronco, or Explorer off-road, the recall serves as an important reminder of the risks posed by engine malfunctions. Ford has assured customers that the necessary repairs will be made at no cost, but the recall underscores the importance of vehicle reliability, especially for those venturing into challenging terrains where reliability is paramount.