DETROIT — The investigation into engine failures associated with Ford vehicles, which lasted for two and a half years, is now concluded by the U.S. government’s auto safety oversight body. This decision follows Ford’s actions to either replace the engines or extend warranties for specific models.
The National Highway Traffic Safety Administration (NHTSA) published details on its website indicating that the investigation identified a significant issue with the intake valves that are prone to fracturing in certain turbocharged engines, specifically the 2.7-liter and 3-liter varieties.
Launched in May 2022, the investigation encompassed over 411,000 vehicles from the 2021 and 2022 model years. This included popular models such as the Ford F-150, Bronco, Edge, and Explorer, along with Lincoln’s Aviator and Nautilus.
The NHTSA focused on severe engine failures attributed to these intake valves breaking, which might then fall into the engine’s cylinder and impact the piston. According to the findings, the forensic examination of the broken valves revealed that high temperatures during production contributed to their fragility, making them susceptible to breaking under regular operating conditions.
Reports indicated that the problematic valves were manufactured between May and October 2021. However, Ford maintained that not all valves produced in this timeframe were defective, asserting that a substantial number of failures occurred before the vehicles reached 20,000 miles.
Additionally, a statistical analysis conducted by the agency aimed to forecast the likelihood of future failures, aligned with Ford’s assertion that these valves typically fail at lower mileages. The NHTSA noted that the majority of affected vehicles had already reported failures related to these valves.
Earlier this year, Ford initiated a recall impacting around 91,000 vehicles containing valves produced during the problematic period. These vehicles will undergo testing and replacement engines if deemed necessary. The automaker has also expanded the warranty coverage for affected vehicles to a duration of 10 years or 150,000 miles.
During the course of the investigation, NHTSA discovered 396 complaints from consumers regarding the engine issues, in addition to 825 warranty claims and 936 engines replaced. Fortunately, there were no reports of any crashes or injuries related to the engine failures.