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Bmadda

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The only problem with this hypothesis is that it was based on a QA issue of the valve metallurgy. Now I am seeing that the problem is with a specific cylinder. Plus, of course most of the failures are around mid 2000 miles because most of the Broncos out there are probably around that range of mileage. SO, I think my post is full of it now.
The fact that the failure is common to a single cylinder SUPPORTS the theory that it's a hardness/heat treat issue, doesn't refute it. Cooling is never 100% uniform in any engine...1 cylinder is always the hottest one, and 1 is the coolest one. It's not to say all the valves wouldn't have failed eventually...one had to be the 1st to go, and the motor doesn't survive that event to be tested further.
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JD 169, 1100 miles. Still running, but I am following this thread very closely. @Lucchese , do you have multiple failures per day or at this point is it just one a day(built date). Do we know approximately how many Lima builds in a day? Would it help calculate a percentage more accurately if tracked JD and mileage of no issue yet out the ones following along here?
 

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not sure if this one is on the list but just happened yesterday/today. Another 2.7
Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] 0349301F-2093-4F30-9C3A-B9CB36623F97

Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] 2E86CE7D-77A1-44EB-8E91-0F477FEBC16B


I forget the user name of that guy but he is on here. The way I remember it sounding when I read his reply post, it sounded like a bearing issue as there was knock on startup.
@Broncitis
 
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JD 169, 1100 miles. Still running, but I am following this thread very closely. @Lucchese , do you have multiple failures per day or at this point is it just one a day(built date). Do we know approximately how many Lima builds in a day? . .
- yes, in upper graph you see there are two days w 3-fails on the same day (209 & 224), and day 166 has 2-fails on same day
- in lower graph, you see the avg(mean) failure-mileage is ~ 2230, the highest so far is 4500, so def appears some type of 'infant mortality' problem
- ? total blown engines nationwide ? - imo roughly 10x the # in OP, however many that ends up today . .
Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] hist - 2.7L Engine Build-Dates - 2022.Jan.19


Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] hist - 2.7L Mileage at Fail - 2022.Jan.19
 

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2022.5 implementation.

Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] 271997535_1076611773115659_69515808799694244_n
 

Carolina Jim

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the avg(mean) failure-mileage is ~ 2230
From what is anecdotally reported - or what forum mechanical experts know - how important is cumulative miles versus heavy petal driving???
 

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Tex

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Assuming an engine failure, is there anything that could be harvested off the vehicle with Forscan for more data on the failure? I'm thinking that I should keep a tablet with Forscan handy and dump all the info before it gets towed to the dealer and the info disappears. I've got a boroscope too, and could probably get some pics of the cylinders.
 

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Lucchese

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not sure if this one is on the list but just happened yesterday/today. Another 2.7
@Broncitis
Brice . . Man, can you ask @Broncitis to share the last-8 of his VIN ? (Nov 5 blown engine in OP - line# 18)
- he could send it to me by DM, so I can lookup the engine build-date on his Nov 5 blown engine, all private & confidential of course -

And much thx these screenshots from Scott Yuen blown engine
- yesterday @Beach_Bum (I think) mentioned this name, but was waiting to see the actual facebook ? posts
- will now add this blown engine in OP
- much appreciated
 

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So, if it's typically Cylinder 5, whats so special about the valves in that one? I would think that if it's a valve retainer or something along those lines, wouldn't it be random across all cylinders? Maybe a head casting problem? Or maybe something to do with cam journals? Are the left/right heads different?
 

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What do you mean by "valve 5"?

Asking for a friend. ;)

Ford Bronco 2.7L blown engine failure list . . 68 so far [Updated: December 13, 2022] 27cyl#
That looks like a burned valve, not a broken (dropped) valve. This won't show impact damage on the spark plug.

It's going to be a very unusual circumstance to have dropped valves isolated to only one cylinder. That would point towards an engine design issue. Perhaps temperature related, or oil starvation related, or both.
 

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I think he means cylinder 5. Is that a head of one of the blown engines?
Yes. Was in a hurry typing. I think most know what’s I was referring to.
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