2.7L and 3.0L engine NHTSA probe expanded -- defective fractured intake valves issue [WARNING: NO TROLLING]

[j_marinelli]

@mpeugeot has like 80K on his. Not sure how close it is to the bad dates but it should be in the thick of it.


@j_marinelli has one around then as well.


Just trying to help.

Currently on around 32k miles. My motor build was a 209er (which was one of the dates with the highest occurrences). Of the failed motors on my day, one user had a motor built 200 in front of me and one 14 after mine. It certainly is a random occurrence to some extent , but I would love for Ford to provide an official response in regards to what they have found as I don't think they ever did. It would be an added bonus (though it would never happen) if Ford was to offer an extended warranty just on the motors that are effected by it (assuming they have isolated the dates down).

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[22OBX]

Then why is NHTSA "including 2022 Bronco (33,106 vehicles)" ?

And including other '22 models "Edge, Explorer, F-150, Aviator, Nautilus" ?

Total "Population: 708,837 (Estimated)"

I’m not sure either because 800 or something out of 708,000 population, statistically speaking, is a very small number. Is all 800 out of all those models and years ?

 

[HotdogThud]

That's fine journalism there. So is the defect associated with the new valve, the old valve, or the first X batches of the new one?

If I'm reading the pdf right, looks like it was a materials defect causing the valves to go brittle when they got hot(ter than normal). switching to a slightly different alloy seems to have remedied it.

 

[Felix808]

Then why is NHTSA "including 2022 Bronco (33,106 vehicles)" ?

And including other '22 models "Edge, Explorer, F-150, Aviator, Nautilus" ?

Total "Population: 708,837 (Estimated)"

22 models started in Aug of 21.
There was a link to the "State" of the engine plant where they had identified issues & made revisions to the 2.7 & parts suppliers at that time.

(Edit)

 

[Lil Mul]

861 claims out of 700k+ engines... color me unconcerned

 

[swamp2]

Thanks @37’s Rule the Wasteland, OP and 2nd poster for all of the details.

 

[nikkgmm]

Sooo, My window sticker date is build 11/27/21. I wonder (and hope) I have the new material utilized.

 

[mpeugeot]

It is.

~82,500 miles.

 

[mpeugeot]

Sooo, My window sticker date is build 11/27/21. I wonder (and hope) I have the new material utilized.

You will get notified when your engine throws a "rapid unscheduled disassembly" code.

 

[nikkgmm]

You will get notified when your engine throws a "rapid unscheduled disassembly" code.

I imagine right when I am in the middle of a river crossing. Has anyone seen an vin number checks we can use for comparison to see who is in the clear?

 

[buzpro]

Issue was addressed by Ford in Oct of 21 so should be a non-issue for most.

So what does all this mean? Mine was built in Aug-July of 2021 .... am I totally hosed?

 

[Art Bell]

So what does all this mean? Mine was built in Aug-July of 2021 .... am I totally hosed?

Sooo, My window sticker date is build 11/27/21. I wonder (and hope) I have the new material utilized.

Read this thread - it's only 289 pages

 

[mpeugeot]

I imagine right when I am in the middle of a river crossing. Has anyone seen an vin number checks we can use for comparison to see who is in the clear?

So what does all this mean? Mine was built in Aug-July of 2021 .... am I totally hosed?

It's by engine date, not VIN number.

 

[Rex21c]

I can't wait till some other news organization brings this up again in 2024 and 2025, cause apparently 800 dead broncos can be beaten a few times.

 

[sniffHound]

Where were these parts made?

Friday NHTSA updated their investigation


3 Investigationsfor 2021 FORD BRONCO
FILTER INVESTIGATIONS BY AFFECTED COMPONENTS
All (3)ENGINE (3)
September 29, 2023 NHTSA ACTION NUMBER: EA23002OPEN INVESTIGATION
Loss of Motive Power
NHTSA Action Number: EA23002
Components ENGINE
Opened From: September 29, 2023–Present
Summary

The Office of Defects Investigation (ODI) received three letters from consumers in March 2022, requesting the investigation of an alleged defect in the valvetrain of model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. The petitioners allege that MY 2021 Ford Bronco vehicles are experiencing catastrophic engine failure resulting in loss of motive power in a variety of driving conditions with no ability to restart. On May 27, 2022, ODI opened a Defect Petition (DP22-001) to evaluate whether to grant or deny the petitioners’ request to investigate. ODI identified 26 Vehicle Owner Questionnaires (VOQs) related to the alleged defect, leading to the granting of the petition. A Preliminary Evaluation (PE22-007) was opened on July 22, 2022, to assess the scope, frequency, and potential safety-related consequences of the alleged defect.
ODI sent an Information Request (IR) letter to Ford requesting material for both the subject 2021 Ford Bronco (25,619 vehicles), as well as additional Ford model/model year vehicle populations equipped with 2.7L EcoBoost engine including the MY 2022 Bronco (33,106 vehicles), MY 2021-2022 F-150 (155,619 vehicles), MY 2021-2022 Edge (6,889 vehicles), and MY 2021-2022 Lincoln Nautilus (8,596 vehicles). In their response to ODI’s request, Ford provided evidence of 328 customer complaints (including field reports), 487 warranty claims, and 809 engine exchanges relating to these vehicle populations. The provided data is comprised of reports of engine failure resulting in several consequences, the most common of which being loss of motive power while the vehicle is in motion. Additionally, analysis of Ford’s IR response revealed that the alleged defect is present across the “Nano” engine family, which includes both the 2.7L and 3.0L EcoBoost engine variants. Vehicles which offer the 3.0L EcoBoost engine as either standard or optional equipment include MY 2021-2022 Explorer and MY 2021-2022 Lincoln Aviator. These model/model year populations will be included within the scope of the engineering analysis and updated population and failure data will be evaluated.
During the investigation, multiple contributing factors were identified which can lead to the fracturing of the intake valves in the subject engines. Ford acknowledged that a fractured intake valve can result in catastrophic engine failure and a loss of motive power and noted that following a valve fracture, a vehicle typically requires a full engine replacement. Ford advised ODI that the defective valves were manufactured out of a specific alloy known as “Silchrome Lite”, which can become excessively hard and brittle if an over-temperature condition occurs during machining of the component. A design modification was implemented in October 2021, which changed the intake valve material to a different alloy known as “Silchrome 1”, that is less susceptible to over-temperature during machine grinding. Ford has identified that the defective intake valves commonly fail early in a vehicle’s life and has suggested that the majority of failures have already occurred.
ODI is opening an Engineering Analysis (EA) in order to 1) evaluate the scope and frequency of allegations across the expanded scope of model/model year vehicle populations equipped with the 2.7L and 3.0L EcoBoost engines, 2) coordinate with NHTSA’s Vehicle Research and Testing Center (VRTC) to evaluate field return parts, 3) analyze the effect of time-in-service on the failure rates for the affected engines, and 4) gather and review additional information to evaluate the effectiveness of Ford’s manufacturing improvements regarding the alleged defect.
To review the reports cited in the attached Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

12 Affected Products
Vehicles

MAKE	MODEL	YEAR
FORD	BRONCO	2021-2022
FORD	EDGE	2021-2022
FORD	EXPLORER	2021-2022
FORD	F-150	2021-2022
LINCOLN	AVIATOR	2021-2022
LINCOLN	NAUTILUS	2021-2022

2 Associated Documents

• OPENING RESUME ODI REPORT IDENTIFICATION NUMBERSINOV-EA23002-10789.pdf 0.048KB
• OPENING RESUME APPROVEDINOA-EA23002-10790.pdf 0.184KB

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