OFFICE OF DEFECTS INVESTIGATIONODI RESUME
U.S. Departmentof Transportation
National Highway
Traffic Safety
Administration

Investigation: EA23002
Prompted By: PE22-007
Date Opened: 09/29/2023
Investigator: Joseph Teitelman
Approver:Tanya Topka
Subject:
Loss of Motive Power

Reviewer:Peter Kivett

MANUFACTURER & PRODUCT INFORMATION
Manufacturer:
Products:
Population:

Ford Motor Company
Model Years 2021-2022 Ford Bronco, Edge, Explorer, and F-150 and Lincoln
Aviator and Nautilus vehicles
708,837 (Estimated)

Problem Description: Under normal driving conditions without warning the vehicle may experience a lossof motive power without restart due to catastrophic engine failure related to analleged faulty valve within 2.7 L and 3.0 L EcoBoost Engines.

FAILURE REPORT SUMMARY
ODI

Manufacturer

EWR D&I

OtherTotal

EWR Field Reports

All Incidents:

5232801,296861*

0Crashes/Fires:

000000Injury Incidents:

000000

Number of Injuries:

000000

Fatality Incidents:

000000

Number of Fatalities:

000000Description of Other: Manufacturer Warranty Claims & Engine Exchanges*Total eliminates duplicates received by the manufacturer

ACTION/SUMMARY INFORMATION
Action:Open Engineering Analysis (EA)

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 ofInvestigation: EA23002

Open Resume Page 1 of 2

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, andpotential 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 (155,619vehicles), 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 fieldreports), 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 mostcommon of which being loss of motive power while the vehicle is in motion. Additionally, analysis ofFord’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 incatastrophic 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 weremanufactured out of a specific alloy known as “Silchrome Lite”, which can become excessively hard andbrittle 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 majorityof failures have already occurred.
ODI is opening an Engineering Analysis (EA) in order to 1) evaluate the scope and frequency ofallegations across the expanded scope of model/model year vehicle populations equipped with the 2.7Land 3.0L EcoBoost engines, 2) coordinate with NHTSA’s Vehicle Research and Testing Center (VRTC) toevaluate field return parts, 3) analyze the effect of time-in-service on the failure rates for the affectedengines, 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.

Investigation: EA23002

Open Resume Page 2 of 2