Another 2.7 bites the dust...

JoergH
Jan 28, 2026

That's a terrible idea, when do we start?

Today at 12:32 am

Folks,

I wanted to document the saga of my Bronco Badlands suffering a catastrophic engine failure while out 4-wheeling.

My Bronco is a 2022 Badlands Sasquatch, built in January 2022, with just over 20,000 miles. Ironically, I had just picked it up from the dealer after completing the 20K service 4 days earlier.

In some ways, I was lucky with the timing. I had already driven about 2.5 hours on the highway to reach the trailhead without any issues. The trail itself was nothing extreme — essentially a dirt fire road, no obstacles, nothing technical. About 15 minutes into the run, I heard a loud BANG. The dash immediately lit up like a Christmas tree and the engine shut off.

I got out, walked around the front, and quickly saw oil pouring from the underside of the Bronco. After a quick assessment, it was clear there was nothing that could be repaired in the field. We ended up dragging it back to the trailhead, and I had AAA tow it to my dealership’s service department.

It took a few days to get the Bronco looked at, but it’s now confirmed that this was a catastrophic internal engine failure. Further inspection showed that a connecting rod exited through the oil pan, so there was significant internal damage.

Discussions with my dealer and @Ford Motor Company are now underway regarding a warranty engine replacement.

After nearly two weeks, I’ve finally been provided a loaner, so at least I’m mobile again. The loaner is currently approved for 10 days, which I don’t expect will be sufficient. Realistically, I’m anticipating at least a month, possibly longer if engines are backordered — but we’ll see. Hopefully I’ll be pleasantly surprised.

I’ll continue to update this thread as things progress, in case it helps anyone else down the road.
OnX Trail Guide and Tread Lightly Member.
4 Door BadSquatch | Soft-top | Velocity Blue | 2.7 Auto
tasker, James77

KCsBronco

Today at 1:00 am

#1
Very sad news indeed!! More of what we thought were the 'Bad old days' of valve issues. Wonder if an oil pan design issue allowing starved oiling mentioned in this article has struck.

Hope Ford gets ya fixed soon..

Cheers
Unicorn, James77
Moderator

Life is a Highway

Today at 2:29 am

#2
So sorry to hear Joerg! Any chance it was related to a prior issue? Hoping for a speedy replacement and then back on the trails!
James77, Jakob1972

Gladesmen

Today at 4:05 am

#3
Dang that is sad. But let’s hope they get you back up and running, and under warranty.
BN 1100, Desert Sand Everglades. Reservation 7/30/20. ordered 1/22/21, reordered 10/15/21 dropped tow and hard top, reordered 3/9/22 changed to Everglades. production date 9/7/22 rescheduled 9/14/22 completed 9/26/22, shipped 10/7/22, arrived 10/31/22, delivered 11/03/22
Unicorn, James77
Moderator Staff member

Administrator

Today at 2:19 pm

#4
I'm glad you were able to get it off the trail and into the dealership, with a warranty replacement. I hope the dealership/insurance is able to get you a loaner until your Bronco is back up and running again. The mileage is somewhat surprising, since most of the 2.7s were failing sooner. I appreciate the thoroughness of your posts and trail drive meetup info, so it'll be interesting to keep up with this thread as you have updates.
2021 Oxford White 2-door non-Sas Mid package 2.7L/10-speed Badlands with MIC top
2021 Carbonized Gray 2-door Sas High package 2.7L/10-speed Badlands with MIC top
Keeping the Jeeps: stock '89 XJ, 3.5" lifted '00 XJ on 31s and '89 MJ
James77

Trusted and Carefree

Today at 5:20 pm

#5
ugh thats lousy. So Sorry that happened.
2023 Wildtrak. "Sometimes you got to get lost, to get found" -J Bronco

Rank IV

Today at 6:04 pm

#6
surprising, since most of the 2.7s were failing sooner.

was that not the valve issue in 21?

I would think that would not be the same issue here... I could be wrong, but I would think a failed valve would not cause a connecting rod to exit the underside of the engine block...

I guess it could, but I would think you would get shut down before that as long as you were not spinning at 10000 rpm...
Laura
Moderator Staff member

Administrator

Today at 6:19 pm

#7
was that not the valve issue in 21?

I would think that would not be the same issue here... I could be wrong, but I would think a failed valve would not cause a connecting rod to exit the underside of the engine block...

I guess it could, but I would think you would get shut down before that as long as you were not spinning at 10000 rpm...

No, you're right and my post was unclear; I didn't have all my logic in a row. I haven't seen other 2.7 failures since those days. I'm sure they exist, and for other reasons too.
2021 Oxford White 2-door non-Sas Mid package 2.7L/10-speed Badlands with MIC top
2021 Carbonized Gray 2-door Sas High package 2.7L/10-speed Badlands with MIC top
Keeping the Jeeps: stock '89 XJ, 3.5" lifted '00 XJ on 31s and '89 MJ
Unicorn

Rank IV

Today at 7:38 pm

#8
No, you're right and my post was unclear; I didn't have all my logic in a row. I haven't seen other 2.7 failures since those days. I'm sure they exist, and for other reasons too.

Your logic is just fine... I was just trying to clarify for my own edification. I wanted to make sure there was not something else that I was missing.
Laura
Moderator Staff member

Administrator

Today at 8:26 pm

#9
Your logic is just fine... I was just trying to clarify for my own edification. I wanted to make sure there was not something else that I was missing.

Well, I know it wasn't my best response work 😆 I was reading it and replying while on a call. I always appreciate clarifications and questions!
2021 Oxford White 2-door non-Sas Mid package 2.7L/10-speed Badlands with MIC top
2021 Carbonized Gray 2-door Sas High package 2.7L/10-speed Badlands with MIC top
Keeping the Jeeps: stock '89 XJ, 3.5" lifted '00 XJ on 31s and '89 MJ

That's a terrible idea, when do we start?

Today at 9:47 pm

#10
I'm glad you were able to get it off the trail and into the dealership, with a warranty replacement. I hope the dealership/insurance is able to get you a loaner until your Bronco is back up and running again. The mileage is somewhat surprising, since most of the 2.7s were failing sooner. I appreciate the thoroughness of your posts and trail drive meetup info, so it'll be interesting to keep up with this thread as you have updates.

I was really surprised that such a catrostophic failure occurred with absolutely no warning and so soon after the 20K service. I'm not saying that the service was the issue, just that they didn't see anything that might have hinted at a problem.

BTW, this could very likely be a value problem, even though after the fact all they see that's obvious is that the connecting rod left the chat via the oil pan. The failure chain could look something like this:

1. Intake valve fractures (the known issue on certain 2.7L/3.0L Nano EcoBoosts)
2. Valve head drops into the cylinder
3. Piston slams into it at speed
4. Piston or wrist pin fails → rod bends or snaps
5. Rod punches through the block or oil pan

“Rod left the chat”

I think that the key here is how the dealer codes this. If the dealer just codes it as “Connecting rod failure due to over-rev / abuse / lubrication issue” then Ford may push back. If they code it as “Catastrophic failure consistent with dropped intake valve leading to secondary rod failure” then Ford is pretty good about it.

Bottom line, a rod doesn’t just decide to exit the oil pan on a maintained, low-mileage Bronco doing mild trail work. Something upstream failed first — and valves are a prime suspect on this engine family.

@Laura, thanks for the kudos, I really appreciate it. I really love this community and want to make it as great as possible place for infomration about Bronco's as I can.
OnX Trail Guide and Tread Lightly Member.
4 Door BadSquatch | Soft-top | Velocity Blue | 2.7 Auto

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