🚨 Recall: Engine valve issue for some 2021-2022 2.7L Broncos and other models

[ffdemoss]

I thought mine was on the hotseat with the amount of issues I have ran into over the 53 weeks over ownership.. It was built in December of 2021.

Issues found so far:
Alternator shielding TSB - fixed
front driveshaft boot material TSB - fixed
Rear camera recall - fixed
Rear Main seal leak - fixed
Extreme oil temps under load(dealer couldn't didn't want to recreate) - ordered a new auxiliary water pump to see if that's the issue

I still love my bronco and wouldn't trade it for anything on the market. It rolled over 45,000 miles yesterday, and hoping to get many hundreds of thousands more

You trust your dealer more than I do. I haven't been to the dealer once for any recall or issue. I'm right in the middle of the failures but I'm at 43,000 miles with no issues. I'll wait for about 80,000 of the 90,000 go through the process before I do.

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[Last Ride Bronco]

Me too. I’m going to let the dealership practice on others first.

 

[VoltageDrop]

The Fundamental issue (speaking as a QC Engineer) is that FoMoCo isn't really a manufacturer any longer, they are a systems integrator assembler.

And I can't stress this enough, it is much much harder to maintain QC with outside vendors compared to inside manufacturing.

Ford got a bad batch of valves. Now, when I say "a bad batch" it may have been one lot, or multiple lots. But they were all made more or less at the same time.

During the machining process, the valves got too hot, and thus they are more brittle than they are supposed to be. Why they got too hot? I don't know. Maybe the sub was running their feeds and speeds too high. Maybe they didn't have enough coolant flow. Guess they missed "parts get brittle due to subcontractor cutting costs" on the P-FMEA.

Ford ended up changing the steel alloy slightly to one that can take more heat during machining.

The data seems to indicate that cracked/sucked valves occur within the first 8000 miles or so.

You appear to understand material science so do you think the test might be more of a static test on the valves themselves? Like, pull the valve covers and measure the hardness of the valve stems? I have no dog in this fight any more but it sorta feels like the gang's all back together and I'm hoping my boys get some closure on this issue.

 

[AZ_Liberty]

You appear to understand material science so do you think the test might be more of a static test on the valves themselves? Like, pull the valve covers and measure the hardness of the valve stems? I have no dog in this fight any more but it sorta feels like the gang's all back together and I'm hoping my boys get some closure on this issue.

My masters is in Physics with a concentration in material science. However, I have no idea what test Ford plans to do.

 

[NCWildtrack]

No shit. My Bronco has been down TWO MONTHS for a MIC top replacement. Do you think I'd trust them to swap my engine? No fucking way.

My small(ish) town Ford dealership is the most incompetent collective of humans I've ever encountered. They couldn't pull off a full service oil change and there is no way in heck they are touching my motor.

 

[2023bronco]

My small(ish) town Ford dealership is the most incompetent collective of humans I've ever encountered. They couldn't pull off a full service oil change and there is no way in heck they are touching my motor.

"Something" happened to one of the rear top windows while replacing the top. So, I'm still sans Bronco. Sigh. I can only imagine what "something" would happen when replacing the engine.

 

[Last Ride Bronco]

Has anyone here ask a trusted local dealership employee about what they are hearing through the grapevine, etc about the recall?

 

[Ducati1098]

Has anyone here ask a trusted local dealership employee about what they are hearing through the grapevine, etc about the recall?

There’s nothing to hear. Dealers won’t get any information until the end of the month when it’s supposed to be released.

 

[Lilj4425]

I pulled this from NHTSA website document and narrows it down to a build date range. And yup I’m right in the middle of it.

Same here. Damn. I got mine in late October 2021.

 

[bcon311]

Any known 22 models with this issue? Pretty sure my 2022 Badlands engine blew this weekend at 9325 mi. I didn't get the engine build date before it was towed to the dealer this morning but the Bronco was built in April 2022. I only saw a date of March 2022 under the hood this morning.

Never any issues. Never been driven rough or abused and drove less than 5k miles a year for the past 2+ years.

Drove fine all day Friday. Saturday evening it started shaking at low speeds in the neighborhood and check engine light came on. Parked at the store and when I tried to drive back home it was shaking and lost just about all the power. Gave it some gas and there was a big boom and a bunch of ratting in the engine and it was dead on the road smoking and wouldn't start. Nothing leaking out of it though.

Towed it home with a tow strap and Ford Roadside picked it up this morning and took it to the dealer. No answers yet - they said maybe they could look at it later this week.

 

[Ducati1098]

Any known 22 models with this issue? Pretty sure my 2022 Badlands engine blew this weekend at 9325 mi. I didn't get the engine build date before it was towed to the dealer this morning but the Bronco was built in April 2022. I only saw a date of March 2022 under the hood this morning.

Never any issues. Never been driven rough or abused and drove less than 5k miles a year for the past 2+ years.

Drove fine all day Friday. Saturday evening it started shaking at low speeds in the neighborhood and check engine light came on. Parked at the store and when I tried to drive back home it was shaking and lost just about all the power. Gave it some gas and there was a big boom and a bunch of ratting in the engine and it was dead on the road smoking and wouldn't start. Nothing leaking out of it though.

Towed it home with a tow strap and Ford Roadside picked it up this morning and took it to the dealer. No answers yet - they said maybe they could look at it later this week.

I would just wait for a diagnosis before worrying about a blown engine. Fuel pumps are far more common and could explain the same/similar symptoms. Also there’s limited information out for the recall anyway right now.

 

[BroncoB]

I would just wait for a diagnosis before worrying about a blown engine. Fuel pumps are far more common and could explain the same/similar symptoms. Also there’s limited information out for the recall anyway right now.

Fuel pumps just die and the car stops running. Shaking, big boom, engine rattling, and smoke? Doesn't sound so good.

 

[Ducati1098]

Fuel pumps just die and the car stops running. Shaking, big boom, engine rattling, and smoke? Doesn't sound so good.

A fuel pump that failed while driving could easily make all of that happen except smoke lol
Regardless, why even speculate what it is with zero information

 

[Art Bell]

Any known 22 models with this issue? Pretty sure my 2022 Badlands engine blew this weekend at 9325 mi. I didn't get the engine build date before it was towed to the dealer this morning but the Bronco was built in April 2022. I only saw a date of March 2022 under the hood this morning.

Never any issues. Never been driven rough or abused and drove less than 5k miles a year for the past 2+ years.

Drove fine all day Friday. Saturday evening it started shaking at low speeds in the neighborhood and check engine light came on. Parked at the store and when I tried to drive back home it was shaking and lost just about all the power. Gave it some gas and there was a big boom and a bunch of ratting in the engine and it was dead on the road smoking and wouldn't start. Nothing leaking out of it though.

Towed it home with a tow strap and Ford Roadside picked it up this morning and took it to the dealer. No answers yet - they said maybe they could look at it later this week.

There have been several 22's with dropped valve blown engines. Not nearly as many as the 21's but still several. Your engine build date is on the oil filler tube. See OP photos in this thread and later posts of '22 Broncos with dropped valves. Can also see '22 dropped valves in the NHTSA reports

Your symptoms are definitely more dropped valve blown engine. Never heard of fuel pump causing all that trouble. "big boom and bunch of rattling in the engine" - Good grief - No way that's a fuel pump

 

[ONEBronco]

Sucks, I am currently looking at a 22 Badlands with the 2.7. Is this an issue that the recall should have resolved the issue or should I stay away from the 22 year?

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