DETROIT (AP) — After a 2 1/2-year investigation, the U.S. government’s auto safety regulator has closed the inquiry into engine failures at Ford. This decision comes after the company took measures such as replacing engines and extending warranties for certain vehicles.
The National Highway Traffic Safety Administration (NHTSA) revealed in documents published Monday that their investigation pointed to a specific defect in the intake valves associated with some 2.7-liter and 3-liter turbocharged engines. When these valves fractured, they could fall into the cylinder and strike the piston, leading to severe engine failures.
The probe, initiated in May 2022, reviewed over 411,000 vehicles from the 2021 and 2022 model years. This included popular models like the Ford F-150, Bronco, Edge, and Explorer, as well as the Lincoln Aviator and Nautilus.
A forensic examination of the fractured intake valves indicated that production conditions at a supplier led to excessive heat during manufacturing, causing the valves to become fragile and prone to breaking under standard engine operation.
An analysis of failure report data revealed that the problematic valves were manufactured between May and October 2021. However, Ford argued that not every valve from that timeframe was defective. They also pointed out that most failures occurred before the affected vehicles reached 20,000 miles of use.
According to the agency’s statistical analysis, which aimed to predict potential failures, findings aligned with Ford’s assertion that valve failures were likely to happen at low mileage, as most vehicles already experienced such issues. Earlier this year, Ford took proactive steps by recalling approximately 91,000 vehicles with potentially defective valves. These vehicles will undergo testing, and if necessary, will be fitted with new engines. Additionally, Ford has extended the warranty for these vehicles to 10 years or 150,000 miles, as noted in the documents.
During the course of this investigation, the agency documented 396 consumer complaints, 825 warranty claims, and 936 engine replacements. Fortunately, there were no reports linking these failures to any accidents or injuries.
