US agency ends investigation into Ford engine failures after recall, warranty extension

DETROIT — The U.S. government's auto safety regulator has ended a two-and-a-half-year investigation into Ford engine failures after the company replaced engines or extended warranties on some vehicles.

The National Highway Traffic Safety Administration says in documents posted on its website Monday that its analysis traces the problem to intake valves that can break inside some 2.7-liter and 3-liter turbocharged engines.

Documents indicate the investigation that began in May 2022 ended up covering more than 411,000 vehicles from the 2021 and 2022 model years, including the Ford F-150 Bronco, Edge and Explorer as well as the Lincoln Aviator and Nautilus.

The agency was investigating catastrophic engine failures caused by intake valves fracturing, falling into the cylinder and hitting the piston.

The documents say a forensic analysis of the fractured valves revealed that when they were manufactured by a parts supplier, the temperature became too high, making them brittle and susceptible to breakage during normal engine use .

An analysis of the failure report data found that the faulty valves were manufactured between May and October 2021, the agency said. Ford maintained that not all valves produced during this period were defective and that a large majority of failures occurred before the vehicles had traveled 20,000 miles.

An agency statistical analysis to predict the number of failures and an analysis of failure reports are generally consistent with Ford's determination that the valves would fail at low mileage, and the majority of vehicles with faulty valves have already experienced an outage, the agency said. .

Earlier this year, Ford recalled about 91,000 vehicles equipped with valves manufactured during the suspicious period. They will be tested and given a new engine if necessary. The company also extended the warranty on vehicles equipped with valves manufactured during that period to 10 years or 150,000 miles, documents show.

During the investigation, the agency said it found 396 customer complaints, 825 warranty claims and 936 engine replacements. No accidents or injuries were reported.

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