'A Step Closer to a Recall': Bronco’s 2.7L Engine

On June 15, 2021, the 6^th generation of Bronco went into production. By July, one owner with the 2.7L engine already had experienced valve failure. Unfortunately, engine failure occurrences continued accumulating as the months went on, and in May 2022, the National Highway Traffic Safety Administration began an investigation on the V-6 EcoBoost.

Read: Should You Worry about the Bronco 2.7-Liter V-6 Investigation?

Expanded Investigation

Now, the NHTSA has expanded its investigation to additional 2021-2022 models with the 2.7L and 3.0L EcoBoost engine, due to an alleged faulty valve issue –– an estimated 708,837 vehicles.

The valves in question were manufactured out of “Silchrome Lite,” an alloy which could become brittle under certain conditions during machining. NHTSA reports that 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.”

The safety administration’s summary states that Ford has suggested most failures have already occurred, as the failures typically happen early, and that following a failure, a full engine replacement usually has been required. In one massive thread, Bronco owner Lucchese has tracked mileage of failures, and all but a few were well under 10,000 miles.

Upgraded to an Engineering Analysis

In addition to expanding the investigation to include not only the Bronco, but also the 2021-2022 Ford Edge, Explorer, F-150, and Lincoln Aviator and Nautilus vehicles, the NHTSA has “upgraded the investigation to an engineering analysis, a step closer to a recall,” says the Detroit Free Press.

In this engineering analysis, the Office of Defects Investigation (ODI) will:

• 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.
• coordinate with NHTSA’s Vehicle Research and Testing Center (VRTC) to evaluate field return parts.
• analyze the effect of time-in-service on the failure rates for the affected engines.
• gather and review additional information to evaluate the effectiveness of Ford’s manufacturing improvements regarding the alleged defect.

Once ODI completes its engineering analysis, a decision will be made on if the engine will need to be recalled.