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2021 Ford F-150

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2021 Ford F-150 do not stand out strongly from the model-year median of 676.

About this comparison →

When problems were reported

Mileage at the reported incident

Limited mileage data: 216 of 1,006 reports include usable mileage. There isn’t enough coverage to show a useful chart.

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Power Train. Review the 312 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 128 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Exterior Lighting. Review the 109 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

13 crash reports4 fire reports6 injury reports

What owners actually said

1,006 reports
Mileage unknown · Sep 14, 2026
Fuel/propulsion System

My husband was driving on the highway with my two daughters in the car when the vehicle stopped driving and he was barely able to pull off the road. It appears to be a defective low-pressure fuel pump. This is an active recall for this model and year, however Ford says that our specific VIN was not involved in the recall. My fam…

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My husband was driving on the highway with my two daughters in the car when the vehicle stopped driving and he was barely able to pull off the road. It appears to be a defective low-pressure fuel pump. This is an active recall for this model and year, however Ford says that our specific VIN was not involved in the recall. My family could have been killed in this incident!

NHTSA ODI #11764236

Mileage unknown · Sep 14, 2026
Exterior Lighting

Led headlight drl strip turned blue on one side. Have seen many with this issue in the led module ballast. Safety concern because its a common running light issue that hinders people from seeing the vehicle as easily.

NHTSA ODI #11764019

Mileage unknown · Sep 13, 2026
Unknown Or Other

Trailer brake controller installed in truck by manufacturer. We wanted to tow our travel trailer and was doing the setup process to test before we left for a trip. We were unable to set the gain for the trailer brake controller. Trailer was connected to truck and plugged in, but unable to change gain or feel brakes when we took …

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Trailer brake controller installed in truck by manufacturer. We wanted to tow our travel trailer and was doing the setup process to test before we left for a trip. We were unable to set the gain for the trailer brake controller. Trailer was connected to truck and plugged in, but unable to change gain or feel brakes when we took a drive around the neighborhood. If we had not taken the steps to test prior to heading out on our trip could have been a serious result. Contacted our local Ford dealer and made an appointment for July 8, 2026. Was told the trailer brake controller connected in the back was not connected. They said this could have happened during manufacturering or just fell out while driving. Still either way could result in serious issues. Not sure if my truck was the only one or are there others on the roads with an issue. If an invoice was provided by the dealership, I have misplaced. They wanted to charge me almost a $100 for them to find it was not connected. The split the cost with me.

NHTSA ODI #11763895

Mileage unknown · Sep 11, 2026
EnginePower Train

I am reporting a severe safety defect where Ford Motor Company's sequential safety recall software updates are actively corrupting powertrain modules and inducing physical mechanical failures while the vehicle is in operation.Following the completion of the 24S55 Engine Intake Valve Recall (which reflashed the PCM and wiped the …

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I am reporting a severe safety defect where Ford Motor Company's sequential safety recall software updates are actively corrupting powertrain modules and inducing physical mechanical failures while the vehicle is in operation.Following the completion of the 24S55 Engine Intake Valve Recall (which reflashed the PCM and wiped the transmission's adaptive learning tables), my 2021 Ford F-150 developed an immediate operational shudder. Shortly after, a forced Over-the-Air (OTA) update for the 26C10 Trailer Brake Module triggered a secondary network reset via the CAN-bus. The intersection of these two software-driven actions caused an operational fault that physically broke the torque converter clutch.A compromised torque converter clutch can cause sudden vehicle stalling, unpredictable acceleration lags, and catastrophic powertrain locking while driving at highway speeds, creating an imminent crash hazard. The local Ford dealership service department confirmed the hardware failure and noted that pushing automated software updates over unstable tables leaves the entire transmission highly vulnerable to total systemic failure.Ford is currently refusing to open an escalation file or address this issue. Because Ford's official remedy for safety recalls 24S55 and 26C10 directly introduces a secondary, severe safety risk to the vehicle's powertrain integrity, I request that NHTSA investigate the technical compatibility and safety of these sequential software updates.

NHTSA ODI #11763680

Mileage unknown · Sep 11, 2026
Service Brakes

ABS Control module and brake booster assembly failed. Vehicle would not crank or start. Disconnected battery negative pole for one minute to reset PCM. Vehicle started. Drove immediately to independent service center without difficulty. Service center confirmed vehicle no start the next morning. Found several DTC codes including…

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ABS Control module and brake booster assembly failed. Vehicle would not crank or start. Disconnected battery negative pole for one minute to reset PCM. Vehicle started. Drove immediately to independent service center without difficulty. Service center confirmed vehicle no start the next morning. Found several DTC codes including U3001 (Control Module Improper Shutdown) U300A (Ignition switch) U0121 (Lost communication with ABS) U0554 (Invalid Data recieved from Accessory Protocol Interface) and U0415 (Invalid Data Received from ABS) Flowchart determined ABS module is bad. Anti Lock Brake System control module failed which rendered the system inoperative. Warning on dash that Anti Lock Brake System failed was prominent among other warnings. (Traction Control, Service Needed, Door Ajar (was closed), Hood ajar (was closed) Assembly was replaced and ABS module reprogrammed by independent service center. They retained the bad assembly.

NHTSA ODI #11763671

Mileage unknown · Sep 9, 2026
Power Train

I’m concerned about the 1080R transmission CDF drum issues that ford had on these year models.Mine is downshifting hard at times not every gear but more between 5-8 gears, or especially coming to a stop light it will down shift hard from 3rd to 1st. Shifting up is not as bad as the downshifting but it still does shift harder tha…

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I’m concerned about the 1080R transmission CDF drum issues that ford had on these year models.Mine is downshifting hard at times not every gear but more between 5-8 gears, or especially coming to a stop light it will down shift hard from 3rd to 1st. Shifting up is not as bad as the downshifting but it still does shift harder than normal.Just doing research on others that had the bad parts in their CDF drum issues seem like mine is having same issues.

NHTSA ODI #11763169

Mileage unknown · Sep 5, 2026
Power Train

When I begin the accelerate from a stopped position I apply the accelerator to begin driving and after a couple seconds after entering the roadway, the vehicle looses power and appears to stall, after a couple more seconds or less the vehicle revs and accelerates very quickly in a jerking fashion and resumes moving forward. Some…

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When I begin the accelerate from a stopped position I apply the accelerator to begin driving and after a couple seconds after entering the roadway, the vehicle looses power and appears to stall, after a couple more seconds or less the vehicle revs and accelerates very quickly in a jerking fashion and resumes moving forward. Sometimes the vehicle will do this several times in a short distance. This loss of power and erratic motion have happened several times when I have entered into traffic form a stopped position and while driving. I took the vehicle to the dealership where I have it regularly serviced and described the problem. After they investigated the issue I described they were able to re-create the issue and told me that the transmission needed repair. I was able to look up similar complaints and have identified that this is a pervasive issue with the 10R80 transmission in this model year, there is a Ford TSB 26-2226 that identifies the symptoms that I experienced and pointed to a defective part in the Transmission that is the likely cause of the erratic behavior of the transmission and power train. Loosing power and stalling unexpectantly while entering an intersection or in traffic could cause a collision and injuring persons or damaging property. The Service Department where I have the vehicle serviced was very aware of the issue with the Transmission and Ford has issued multiple Technical Service Bulletins to include TSB 26-2046 and TSB-26-2226. This may also be related to Ford Special Field Action 25-L02 regarding the Transmission Control Module and/ or the Safety Recall Notice Ford Number 26S48,/ NHTSA 26V402.

NHTSA ODI #11762326

Mileage unknown · Sep 4, 2026
Fuel/propulsion System

We broke down because the fuel pump broke, which has a recall out there. We had stopped at Buc-ee’s for a break and when we got back to the truck, it wouldn’t start back up. We got it fixed at Banner Ford and were forced to pay $1822.50 for a fix that a known recall is out for that they claim there’s no remedy for. But, then you…

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We broke down because the fuel pump broke, which has a recall out there. We had stopped at Buc-ee’s for a break and when we got back to the truck, it wouldn’t start back up. We got it fixed at Banner Ford and were forced to pay $1822.50 for a fix that a known recall is out for that they claim there’s no remedy for. But, then you’re telling me you can fix it for $1800. It makes no sense that we have to pay for something that there’s a recall for. We are just trying to get our money back.

NHTSA ODI #11762158

Mileage unknown · Sep 4, 2026
Steering

Subject: Steering Rack Failure Reimbursement Request, VIN [XXX] To Whom It May Concern, I am requesting review and reimbursement for an electronic steering rack replacement on my 2021 Ford truck, VIN [XXX]. The electronic steering fault first appeared at start-up and when turning the wheel to full lock. Initially, I could pul…

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Subject: Steering Rack Failure Reimbursement Request, VIN [XXX] To Whom It May Concern, I am requesting review and reimbursement for an electronic steering rack replacement on my 2021 Ford truck, VIN [XXX]. The electronic steering fault first appeared at start-up and when turning the wheel to full lock. Initially, I could pull over, shut the truck off, restart it, and the warning would clear. After a battery replacement, battery monitoring system reset, and multiple steering relearns, the steering failed completely. When the failure occurred, steering became extremely difficult. After hitting a bump, the steering wheel jerked suddenly and caused pain to my hand and thumb. This also created a serious safety risk for me and others on the road due to the reduced ability to steer. The dealership replaced the electronic steering rack at a cost of over $2,000. The truck had only about 40,000 miles at the time. I later found Ford Recall 21S28, which appears to cover certain trucks built between XXX. Based on my VIN and build date, my truck appears to fall within that range, but the dealership advised my VIN was not included. Given the low mileage, safety risk, and apparent build-date match with Recall 21S28, I request that Ford and NHTSA review my vehicle’s eligibility under this recall or any related program and reimburse me for the repair. Thank you, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI #11762148

Mileage unknown · Sep 3, 2026
Power Train

I am reporting a serious safety-related transmission issue involving my 2021 Ford F-150 equipped with the 10R80 automatic transmission. On multiple occasions during normal driving, the transmission has behaved unpredictably and, at times, dangerously. The transmission has suddenly lost the selected gear, slipped or failed to en…

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I am reporting a serious safety-related transmission issue involving my 2021 Ford F-150 equipped with the 10R80 automatic transmission. On multiple occasions during normal driving, the transmission has behaved unpredictably and, at times, dangerously. The transmission has suddenly lost the selected gear, slipped or failed to engage, shifted violently, experienced significant RPM flares, unexpectedly downshifted, and harshly clunked into first and second gear while coming to a stop. These events have occurred under a variety of normal driving conditions, including while accelerating, merging onto a highway, making turns, crossing intersections, traveling at highway speeds, driving in stop-and-go traffic, and coming to a stop at red lights. In several instances, the vehicle did not provide the expected acceleration or propulsion when commanded, creating a potentially dangerous situation because I could not reliably predict how or when the truck would respond to throttle input. Of particular concern is the possibility of losing propulsion or experiencing an unexpected gear change while merging into traffic, crossing an intersection, or traveling at highway speed. The unpredictable nature of the transmission makes it difficult to safely operate the vehicle and creates a significant risk of a collision. I believe these symptoms may be related to the known 10R80 CDF clutch-cylinder/sleeve issue. Ford technical information has identified axial movement of the CDF sleeve as a condition that can affect hydraulic circuits and contribute to abnormal transmission operation. The symptoms I have experienced appear consistent with this type of failure. Because these transmission problems have occurred repeatedly and under multiple driving conditions, I believe this issue should be investigated as a potential motor-vehicle safety defect rather than treated solely as a drivability or comfort concern.

NHTSA ODI #11761795

Official recalls

29

26V489000 · Back Over Prevention:display Function; Back Over Prevention:software

Jul 28, 2026

Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 and 2023-2026 F-250 SD vehicles equipped with 8-inch SYNC infotainment screens. A software error may cause the rearview camera image to be obstructed by the infotainment home screen menu when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."

Consequence & remedy

Consequence: An obstructed rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.

Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air (OTA) update, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 7, 2026. Additional letters will be sent once the remedy is available, anticipated in September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C37. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 31, 2026.

Additional source detail variants (2)

Back Over Prevention:display Function

Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 and 2023-2026 F-250 SD vehicles equipped with 8-inch SYNC infotainment screens. A software error may cause the rearview camera image to be obstructed by the infotainment home screen menu when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."

Consequence: An obstructed rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.

Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air (OTA) update, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 7, 2026. Additional letters will be sent once the remedy is available, anticipated in September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C37. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 31, 2026.

Back Over Prevention:software

Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 and 2023-2026 F-250 SD vehicles equipped with 8-inch SYNC infotainment screens. A software error may cause the rearview camera image to be obstructed by the infotainment home screen menu when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rear Visibility."

Consequence: An obstructed rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.

Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air (OTA) update, free of charge. Interim letters, notifying owners of the safety risk, were mailed August 7, 2026. Additional letters will be sent once the remedy is available, anticipated in September 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C37. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 31, 2026.

26V402000 · Power Train:automatic Transmission

Jun 24, 2026

Ford Motor Company (Ford) is recalling certain 2018-2021 Navigator, Expedition, 2020-2021 Explorer, Lincoln Aviator, and 2021 F-150 vehicles. The transmission park pawl may engage while the vehicle is in motion, resulting in park system damage.

Consequence & remedy

Consequence: Park system damage may result in a vehicle rollaway, increasing the risk of a crash.

Remedy: Dealers will update the powertrain control module software, and inspect and replace any damaged transmission components as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed July 10, 2026. Additional letters will be sent once the remedy is available, anticipated in April 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S48. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on June 26, 2026.

26V104000 · Electrical System: Integrated Trailer Brake Control; Exterior Lighting:tail Lights

Feb 20, 2026

Ford Motor Company (Ford) is recalling certain 2021-2026 F-150, 2022-2026 F-250 SD, F-350 SD, F-450 SD, F-550 SD, Maverick, 2024-2026 Ranger, 2023-2026 F-600 SD, 2022-2027 Lincoln Navigator, Expedition, and 2026 E-Transit vehicles. When towing a trailer, the integrated trailer module (ITRM) may lose communication with the vehicle, possibly causing a loss of brake and turn signal lights, or a loss of brake function. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: Trailer lights or brakes that do not function can reduce the driver’s ability to control the trailer and decrease the trailers visibility to other road users, increasing the risk of a crash.

Remedy: The integrated trailer module software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. Owner notification letters were mailed March 25, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C10. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 17, 2026.

Additional source detail variants (2)

Exterior Lighting:tail Lights

Ford Motor Company (Ford) is recalling certain 2021-2026 F-150, 2022-2026 F-250 SD, F-350 SD, F-450 SD, F-550 SD, Maverick, 2024-2026 Ranger, 2023-2026 F-600 SD, 2022-2027 Lincoln Navigator, Expedition, and 2026 E-Transit vehicles. When towing a trailer, the integrated trailer module (ITRM) may lose communication with the vehicle, possibly causing a loss of brake and turn signal lights, or a loss of brake function. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: Trailer lights or brakes that do not function can reduce the driver’s ability to control the trailer and decrease the trailers visibility to other road users, increasing the risk of a crash.

Remedy: The integrated trailer module software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. Owner notification letters were mailed March 25, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C10. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 17, 2026.

Electrical System: Integrated Trailer Brake Control

Ford Motor Company (Ford) is recalling certain 2021-2026 F-150, 2022-2026 F-250 SD, F-350 SD, F-450 SD, F-550 SD, Maverick, 2024-2026 Ranger, 2023-2026 F-600 SD, 2022-2027 Lincoln Navigator, Expedition, and 2026 E-Transit vehicles. When towing a trailer, the integrated trailer module (ITRM) may lose communication with the vehicle, possibly causing a loss of brake and turn signal lights, or a loss of brake function. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, " Lamps, Reflective Devices, and Associated Equipment."

Consequence: Trailer lights or brakes that do not function can reduce the driver’s ability to control the trailer and decrease the trailers visibility to other road users, increasing the risk of a crash.

Remedy: The integrated trailer module software will be updated by a dealer, or through an over-the-air (OTA) update, free of charge. Owner notification letters were mailed March 25, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C10. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning March 17, 2026.

25V729000 · Visibility:sun/moon Roof Assembly

Oct 24, 2025

Ford Motor Company (Ford) is recalling certain 2021-2022 Expedition, Lincoln Navigator, 2021-2023 F-150, 2022 F-250 SD, F-350 SD, and F-450 SD vehicles. The moonroof wind deflector clips may be inadequately attached to the moonroof frame, which can result in the wind deflector detaching from the vehicle.

Consequence & remedy

Consequence: A detached wind deflector can become a road hazard and increase the risk of a crash.

Remedy: Dealers will inspect and repair the moonroof wind deflector as necessary, free of charge. Owner notification letters were mailed November 10, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25SB7. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning October 30, 2025.

25V455000 · Fuel System, Gasoline:delivery:fuel Pump

Jul 7, 2025

Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.

Consequence & remedy

Consequence: An engine stall increases the risk of a crash.

Remedy: Dealers will replace the low pressure fuel pump on super duty vehicles and update the powertrain control module (PCM) software on all other affected vehicles, free of charge. Owner notification letters were mailed July 27, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S75.

25V348000 · Exterior Lighting:back Up Lights

May 23, 2025

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles equipped with the Onboard Scales feature that were repaired incorrectly under recall 24V443. An over-the-air software update to the body control module (BCM) may have disabled both reverse lights.

Consequence & remedy

Consequence: Inoperative reverse lights may fail to alert others that the vehicle is reversing, increasing the risk of a crash.

Remedy: Dealers will update the body control module software, free of charge. Owner notification letters were mailed on June 27, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S57.

25V315000 · Back Over Prevention:software

May 9, 2025

Ford Motor Company (Ford) is recalling certain 2021-2024 Bronco, F-150, 2021-2024 Edge, 2022-2025 Escape, F-250, F-350, F-450, F-550, F-600, 2022-2024 Expedition, 2022-2025 Transit, 2021-2023 Mach-E, 2024 Ranger, Mustang, 2021-2023 Lincoln Nautilus, 2022-2024 Navigator, and 2023-2024 Corsair vehicles. A software error may cause the rearview camera image to delay, freeze, or not display when the vehicle is in reverse.

Consequence & remedy

Consequence: A frozen or missing rearview camera image can reduce the driver's view behind the vehicle, increasing the risk of a crash.

Remedy: The accessory protocol interface module (APIM) software will be updated by a dealer or through an over-the-air update, free of charge. This will be a phased campaign, with the remedy becoming available in different phases based on model and model years. Interim letters notifying owners of the safety risk were mailed on June 26, 2025. Additional letters will be mailed once the final remedy is available on each phase. Owner notification letters were sent on October 8, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S49.

25V169000 · Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Mar 14, 2025

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles previously repaired incorrectly under recall number 22V-188. The Diagnostic Trouble Code (DTC) for low transmission fluid pressure may falsely activate and cause the transmission to unexpectedly shift into neutral.

Consequence & remedy

Consequence: An unexpected shift into neutral will cause a loss of drive power and increase the risk of a crash.

Remedy: Dealers will update the Powertrain Control Module (PCM) software, free of charge. Owner notification letters were mailed April 22, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S24.

25V132000 · Electrical System: Integrated Trailer Brake Control

Feb 28, 2025

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150, 2022 Maverick, Expedition, Lincoln Navigator, F-250, F-350, F-450, and F-550 vehicles previously repaired incorrectly under recall number 22V-193. Due to a software error, a towed trailer equipped with an electric or electric-over hydraulic brake system may not brake.

Consequence & remedy

Consequence: Loss of trailer brake functionality can extend the distance required to stop, increasing the risk of a crash.

Remedy: Dealers will update the integrated trailer brake control module software, free of charge. Owner notification letters were mailed April 11, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S18.

24V852000 · Equipment:other:labels

Nov 8, 2024

Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."

Consequence & remedy

Consequence: Without a label that shows the proper restraint usage guidelines, the occupants may have an increased risk of injury in the event of a crash.

Remedy: Ford will mail owners the warning labels, free of charge. Owner notification letters were mailed December 19, 2024. Owners may call Ford customer service at 1-866-436-7332. Ford's number for this recall is 24C39.

24V635000 · Engine And Engine Cooling:engine:hard Parts Internal/mechanical

Aug 23, 2024

Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.

Consequence & remedy

Consequence: A loss of drive power increases the risk of a crash.

Remedy: Dealers will perform an engine cycle test and replace the engine as necessary, free of charge. Owner notification letters were mailed July 3, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S55.

24V443000 · Electrical System:body Control Module:software; Exterior Lighting:back Up Lights

Jun 14, 2024

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles equipped with the Onboard Scales feature. An over-the-air software update to the body control module (BCM) may have disabled both reverse lights.

Consequence & remedy

Consequence: Disabled reverse lights cannot alert others that the vehicle is reversing, increasing the risk of a crash.

Remedy: Dealers will update the body control module software, free of charge. Owner notification letters are were mailed June 26, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S38.

Additional source detail variants (2)

Electrical System:body Control Module:software

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles equipped with the Onboard Scales feature. An over-the-air software update to the body control module (BCM) may have disabled both reverse lights.

Consequence: Disabled reverse lights cannot alert others that the vehicle is reversing, increasing the risk of a crash.

Remedy: Dealers will update the body control module software, free of charge. Owner notification letters are were mailed June 26, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S38.

Exterior Lighting:back Up Lights

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles equipped with the Onboard Scales feature. An over-the-air software update to the body control module (BCM) may have disabled both reverse lights.

Consequence: Disabled reverse lights cannot alert others that the vehicle is reversing, increasing the risk of a crash.

Remedy: Dealers will update the body control module software, free of charge. Owner notification letters are were mailed June 26, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S38.

23V896000 · Power Train:axle Hubs

Dec 22, 2023

Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 vehicles equipped with the Trailer Tow Max Duty package and a 9.75-inch heavy duty axle with a 3/4 float axle design. The rear axle hub bolt may fatigue and break, which can result in damage to the axle hub splines.

Consequence & remedy

Consequence: Damaged axle hub splines can result in a vehicle rollaway when the vehicle is in park without the parking brake applied or cause a loss of drive power. Both of these conditions can increase the risk of a crash.

Remedy: Dealers will replace the left and right rear axle shaft assemblies, free of charge. Owner notification letters were mailed on May 9, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S65.

23V509000 · Parking Brake:electrical

Jul 21, 2023

Ford Motor Company (Ford) is recalling certain 2021-2023 F-150 vehicles equipped with a single exhaust system. Contact with the rear axle housing may damage the wiring harness, causing the electric parking brake to activate unexpectedly.

Consequence & remedy

Consequence: Unexpected activation of the electric parking brake while driving increases the risk of a crash.

Remedy: Dealers will install a protective tie strap, tape wrap, and replace the harness as necessary, free of charge. Owner notification letters were mailed February 12, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S35.

23V163000 · Visibility:windshield Wiper/washer:linkages

Mar 10, 2023

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The windshield wiper arms may break, causing the windshield wipers to fail.

Consequence & remedy

Consequence: Inoperative windshield wipers can reduce visibility in certain conditions, increasing the risk of a crash.

Remedy: Dealers will inspect and replace the wiper arms, as necessary, free of charge. Owner notification letters were mailed December 13, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S10. This recall expands previous recall number 22V-250.

22V842000 · Visibility:windshield Wiper/washer:motor

Nov 15, 2022

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. The front windshield wiper motor may become inoperative, causing the wipers to fail.

Consequence & remedy

Consequence: Inoperative windshield wipers can reduce visibility in certain conditions, increasing the risk of a crash.

Remedy: Dealers will replace the front windshield wiper motor, free of charge. Owner notification letters were mailed June 30, 2023. Remedy parts are expected in the 3rd Quarter of 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S71. This recall expands previous recall number 22V-142.

22V623000 · Power Train:driveline:driveshaft; Structure:frame And Members:underbody Shields

Aug 12, 2022

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence & remedy

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios increases the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft, as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed September 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S53.

Additional source detail variants (2)

Structure:frame And Members:underbody Shields

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios increases the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft, as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed September 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S53.

Power Train:driveline:driveshaft

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios increases the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft, as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed September 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S53.

22V414000 · Fuel System, Gasoline:storage

Jun 10, 2022

Ford Motor Company (Ford) is recalling one 2021 F-150 vehicle. A single vehicle may have been assembled without a fuel tank front attachment resulting in an unsecured fuel tank attachment strap.

Consequence & remedy

Consequence: An improperly attached fuel tank increases the risk of a fuel leak and potential for fire.

Remedy: Dealers will inspect and repair (if necessary) the fuel tank strap bracket, free of charge. Owner notification letters were mailed July 1, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S42.

22V250000 · Visibility:windshield Wiper/washer:linkages

Apr 14, 2022

Ford Motor Company (Ford) is recalling certain 2020-2021 F-150, Expedition, 2020-2022 Super Duty F-250, F-350, F-450, F-550, and 2020-2021 Lincoln Navigator vehicles. The windshield wiper arms may break, causing the windshield wipers to fail.

Consequence & remedy

Consequence: Inoperative windshield wipers can reduce visibility in certain driving conditions, increasing the risk of a crash.

Remedy: Dealers will replace both front windshield wiper arms, free of charge. Interim owner notification letters, informing owners of the safety risk, were mailed on May 24, 2022. Remedy parts are expected to be available 3rd Quarter 2022. Owner notification letters were mailed on October 21, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S26.

22V188000 · Power Train:automatic Transmission:control Module (tcm/pcm/tecm)

Mar 25, 2022

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The Diagnostic Trouble Code (DTC) for low transmission fluid pressure may falsely activate and cause the transmission to unexpectedly shift into neutral.

Consequence & remedy

Consequence: An unexpected shift into neutral will cause a loss of drive power and increase the risk of a crash.

Remedy: Dealers will update the Powertrain Control Module (PCM) software, free of charge. Owner notification letters were mailed on April 12, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S15.

22V193000 · Electrical System: Integrated Trailer Brake Control

Mar 25, 2022

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150, 2022 Maverick, Expedition, Lincoln Navigator, F-250, F-350, F-450, and F-550 vehicles. Due to a software error, a towed trailer equipped with an electric or electric-over hydraulic brake system may not brake.

Consequence & remedy

Consequence: Loss of trailer brake functionality could result in extended stopping distance, increasing the risk of a crash.

Remedy: Dealers will update the integrated trailer brake control module software, free of charge. Owner notification letters were mailed April 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S17.

22V142000 · Visibility:windshield Wiper/washer:motor

Mar 11, 2022

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The front windshield wiper motor may become inoperative, causing the wipers to fail.

Consequence & remedy

Consequence: Inoperative windshield wipers can reduce visibility in certain conditions, increasing the risk of a crash.

Remedy: Dealers will replace the front windshield wiper motor, free of charge. Owner notification letters were mailed June 22, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S12.

21V986000 · Power Train:driveline:driveshaft; Structure:frame And Members:underbody Shields

Dec 16, 2021

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence & remedy

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios can increase the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed February 4, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S56.

Additional source detail variants (2)

Structure:frame And Members:underbody Shields

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios can increase the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed February 4, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S56.

Power Train:driveline:driveshaft

Ford Motor Company (Ford) is recalling certain 2021-2022 F-150 vehicles. Underbody heat and noise insulators may loosen and contact the aluminum driveshaft, which could damage the driveshaft and cause it to fracture.

Consequence: A fractured driveshaft can cause a loss of drive power, or a loss of vehicle control if the driveshaft contacts the ground. Additionally, unintended movement could occur while parked if the parking brake is not engaged. Any of these scenarios can increase the risk of a crash.

Remedy: Dealers will inspect and repair the driveshaft as necessary, and properly attach the underbody insulators, free of charge. Owner notification letters were mailed February 4, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S56.

21V805000 · Air Bags:sensor:side Impact; Air Bags:side/window

Oct 15, 2021

Ford Motor Company (Ford) is recalling certain 2022 Super Duty F-250, F-350, 2021 F-150, Expedition, and Lincoln Navigator vehicles. The front-door side impact pressure sensor modules may have been damaged during supplier assembly, which can cause the side impact air bags to not deploy properly in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 214, "Side Impact Protection."

Consequence & remedy

Consequence: An air bag that does not deploy properly during a crash increases the risk of injury.

Remedy: Dealers will replace the driver and passenger front door side impact sensors, free of charge. Owner notification letters were mailed November 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C26.

Additional source detail variants (2)

Air Bags:sensor:side Impact

Ford Motor Company (Ford) is recalling certain 2022 Super Duty F-250, F-350, 2021 F-150, Expedition, and Lincoln Navigator vehicles. The front-door side impact pressure sensor modules may have been damaged during supplier assembly, which can cause the side impact air bags to not deploy properly in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 214, "Side Impact Protection."

Consequence: An air bag that does not deploy properly during a crash increases the risk of injury.

Remedy: Dealers will replace the driver and passenger front door side impact sensors, free of charge. Owner notification letters were mailed November 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C26.

Air Bags:side/window

Ford Motor Company (Ford) is recalling certain 2022 Super Duty F-250, F-350, 2021 F-150, Expedition, and Lincoln Navigator vehicles. The front-door side impact pressure sensor modules may have been damaged during supplier assembly, which can cause the side impact air bags to not deploy properly in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 214, "Side Impact Protection."

Consequence: An air bag that does not deploy properly during a crash increases the risk of injury.

Remedy: Dealers will replace the driver and passenger front door side impact sensors, free of charge. Owner notification letters were mailed November 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C26.

21V653000 · Seat Belts:front:webbing

Aug 23, 2021

Ford Motor Company (Ford) is recalling certain 2021 F-150 Super Cab vehicles. The front seatbelt webbing may be incorrectly routed.

Consequence & remedy

Consequence: A misrouted seatbelt may not adequately restrain an occupant in a crash, increasing the risk of injury.

Remedy: Owners are advised to perform a preliminary self-inspection of the front seatbelts. If the passenger-side seatbelt fails inspection, owners should not use the passenger seat until the repair is performed. If the driver-side seatbelt fails inspection, owners should not drive their vehicle until the repair is performed. Dealers will inspect the front seatbelts and, if the webbing is misrouted, will replace the seatbelt retractor and pretensioner, free of charge. Owner notification letters were mailed on October 14, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C20.

21V533000 · Service Brakes, Hydraulic

Jul 15, 2021

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The electronic brake booster may leak brake fluid into the electronic control unit, which could result in reduced braking performance.

Consequence & remedy

Consequence: Reduced braking performance can increase the risk of a crash.

Remedy: Dealers will replace the electronic brake booster assembly, free of charge. Owner notification letters were mailed on July 28, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S33.

21V407000 · Steering; Steering:gear Box (other Than Rack And Pinion); Steering:rack And Pinion

May 29, 2021

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The steering gear may have internal damage, which could result in difficulty steering, or the inability to rotate the steering wheel while driving.

Consequence & remedy

Consequence: Loss of steering control can increase the risk of a crash.

Remedy: Owners are advised to not drive their vehicles until the repair is complete. Vehicles will be towed in for service, and dealers will remove and replace the steering gear, free of charge. Owner notification letters were mailed on June 4, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S28.

Additional source detail variants (3)

Steering:rack And Pinion

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The steering gear may have internal damage, which could result in difficulty steering, or the inability to rotate the steering wheel while driving.

Consequence: Loss of steering control can increase the risk of a crash.

Remedy: Owners are advised to not drive their vehicles until the repair is complete. Vehicles will be towed in for service, and dealers will remove and replace the steering gear, free of charge. Owner notification letters were mailed on June 4, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S28.

Steering:gear Box (other Than Rack And Pinion)

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The steering gear may have internal damage, which could result in difficulty steering, or the inability to rotate the steering wheel while driving.

Consequence: Loss of steering control can increase the risk of a crash.

Remedy: Owners are advised to not drive their vehicles until the repair is complete. Vehicles will be towed in for service, and dealers will remove and replace the steering gear, free of charge. Owner notification letters were mailed on June 4, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S28.

Steering

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The steering gear may have internal damage, which could result in difficulty steering, or the inability to rotate the steering wheel while driving.

Consequence: Loss of steering control can increase the risk of a crash.

Remedy: Owners are advised to not drive their vehicles until the repair is complete. Vehicles will be towed in for service, and dealers will remove and replace the steering gear, free of charge. Owner notification letters were mailed on June 4, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S28.

21V381000 · Power Train:driveline:driveshaft

May 24, 2021

Ford Motor Company (Ford) is recalling certain 2021 F-150 vehicles. The two-piece driveshafts may have been improperly assembled, which could result in driveshaft separation.

Consequence & remedy

Consequence: Driveshaft separation may result in a sudden loss of drive power, or unintended vehicle movement if the vehicle is in park without the parking brake applied, increasing the risk of a crash.

Remedy: Dealers will inspect the driveshaft, and replace it if necessary, free of charge. Owner notification letters were mailed on June 15, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S25.

21V090000 · Visibility:windshield; Visibility:windshield:critical Fasteners

Feb 18, 2021

Ford Motor Company (Ford) is recalling certain 2021 F-150 and 2020-2021 F-250, F-350, F-450, and F-550 Super Duty vehicles. During manufacturing, the windshield may not have been properly bonded to the vehicle, allowing it to detach in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 212, "Windshield Mounting."

Consequence & remedy

Consequence: In the event of a crash, if the windshield separates from the vehicle, it can increase the risk of injury.

Remedy: Ford will notify owners, and dealers will remove and reinstall the windshield, free of charge. The recall began April 16, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C06.

Additional source detail variants (2)

Visibility:windshield:critical Fasteners

Ford Motor Company (Ford) is recalling certain 2021 F-150 and 2020-2021 F-250, F-350, F-450, and F-550 Super Duty vehicles. During manufacturing, the windshield may not have been properly bonded to the vehicle, allowing it to detach in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 212, "Windshield Mounting."

Consequence: In the event of a crash, if the windshield separates from the vehicle, it can increase the risk of injury.

Remedy: Ford will notify owners, and dealers will remove and reinstall the windshield, free of charge. The recall began April 16, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C06.

Visibility:windshield

Ford Motor Company (Ford) is recalling certain 2021 F-150 and 2020-2021 F-250, F-350, F-450, and F-550 Super Duty vehicles. During manufacturing, the windshield may not have been properly bonded to the vehicle, allowing it to detach in a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 212, "Windshield Mounting."

Consequence: In the event of a crash, if the windshield separates from the vehicle, it can increase the risk of injury.

Remedy: Ford will notify owners, and dealers will remove and reinstall the windshield, free of charge. The recall began April 16, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C06.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA23002 · Loss Of Motive Power

Opened Sep 29, 2023 · Closed Oct 31, 2024

Status: closed (inferred from source dates) · Engine

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family.  If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.