Ford EcoBoost Engine Failure Investigation Expands

 Ford EcoBoost Engine Failure Investigation ExpandsNHTSA Investigating Faulty Intake Valve Design in Ford EcoBoost Engines

Ford Motor Company has been replacing faulty EcoBoost engines in certain Ford Bronco SUVs, Ford Edge, Ford F-150 pickup trucks, and Lincoln Nautilus, but now federal safety regulators are stepping up an investigation into the problematic intake valve design in the engines.

The U.S. National Highway Traffic Safety Administration (NHTSA) initially launched an investigation back in May 2022 into the 2.7-litre EcoBoost V6. However, earlier this fall, the federal safety agency probe found that thousands of vehicles may experience engine failure due to a faulty intake valve design. The NHTSA probe is now conducting an engineering analysis to review what happened and compare the faulty parts with replacement parts that Ford began using in late 2021. It takes the issue one step closer to potentially becoming a recall.

Indeed, these are popular SUVs and pickup trucks that consumers believed were “built tough” and “built for America,” but recently they began experiencing catastrophic engine failure at an alarming rate.

The investigation began with roughly 25,000 Ford Broncos, but now Ford has a big problem on its hands with roughly 708,000 vehicles affected including the 2021-2022 Bronco, Edge, F-150, and Lincoln Nautilus equipped with the 2.7-litre EcoBoost engine. Furthermore, U.S. regulators are also looking into Ford’s 3.0-litre EcoBoost V6 installed in the 2021-2022 Ford Explorer and Lincoln Aviator.  These engines were designed to provide increased horsepower and torque as well as better fuel efficiency.

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Federal safety investigators learned the automaker has received at least 328 consumer complaints and 487 warranty claims and they are performing a new engineering analysis. Owners reported their vehicle’s engine failed and there was without warning a loss of motive power while the engine was in motion. Also, the vehicles would not restart after turning off.

Ford has acknowledged multiple factors could lead to fractured intake valves in these problematic engines. Once a vehicle’s intake valve breaks, there may be catastrophic engine failure as well as a loss of motive power. Also, the vehicles with valve fractures will require a complete engine replacement.

At least 800 EcoBoost V6 engines have been replaced by Ford so far in the United States as a direct result of this problem.

The problem started after Ford implemented a design modification to its intake valves in October 2021. The automaker began manufacturing them out of a different alloy known as “Silichrome Lite.” The problem is this alloy becomes hard and brittle if a high-temperature condition occurs during the machining grinding done in the manufacturing process.

Ford reports the problematic valves will most likely fail early in new vehicles, such as within a few hundred or thousand miles. Also, Ford stated that most engines that are subject to failing, have already failed. So far, at least 800 EcoBoost V6 engines have been replaced by Ford due to this issue.

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Do you own a defective Ford Bronco, Ford Edge, Ford F-150 pickup truck or a Lincoln Nautilus with repeated problems, electrical issues, or a dangerous safety issue? If that sounds familiar, you don’t have to wait for a recall before you reach out to an experienced attorney and get help. California Lemon Law Attorney James Johnson will review your case and let you know if it qualifies as a lemon.

We highly recommend Ford owners with engine or other problems obtain invoices for all repairs and recall visits from the dealership. These documents will support your potential case. Should the vehicle experience repeated issues or become a safety risk, these documents support the Lemon Law Claim. Contact us for a free case review at 1-(877) 465-8161 or read on for answers to frequently asked questions

Published on Dec. 7, 2023

Disclaimer: This article provides general information about vehicles that may be covered by the California lemon law. However, the lemon law has very specific requirements that must be met for your vehicle to be considered a lemon. Every case has a unique set of circumstances and there are specific criteria that must be met for the lemon law to apply. It is imperative that you take immediate action if you believe your vehicle may qualify.











James Johnson ESQ