← New search

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 · Jan 18, 2026
Exterior Lighting

The daytime running lamp assemblies on both headlights are failing. On the driver's side, the entire LED array around the outside of the headlight has failed. On the passenger's side, the vertical LED array is extremely dim and will probably fail soon. The topmost horizontal LED array on the passenger's side is currently the onl…

Read full complaint

The daytime running lamp assemblies on both headlights are failing. On the driver's side, the entire LED array around the outside of the headlight has failed. On the passenger's side, the vertical LED array is extremely dim and will probably fail soon. The topmost horizontal LED array on the passenger's side is currently the only array still working. Obviously this poses a safety risk as these lights provide visibility of the vehicle in low light and low visibility driving conditions. I have seen many forum posts and YouTube videos about this problem and as the parts are integrated into the headlamp assembly, the only way to fix is a complete replacement of the assembly which is a $2000-$2500 repair PER ASSEMBLY. This problem appears to be related to heat dissipation issues, indicating a manufacturers defect. In older model vehicles, a daytime running lamp used to be a $5-$20 bulb replacement. The fact that I now have no choice but to pay $2000 to restore functionality of a safety feature is completely unacceptable. At the very least, Ford should redesign the LED module to be replaceable independent of the larger assembly, reducing the cost to the owner.

NHTSA ODI #11711779

Mileage unknown · Jan 18, 2026
EngineFuel/propulsion SystemUnknown Or Other

Guessing the date below Truck shuts off when trying to take off and go. This has happened a few times and even pulling onto a main highway. This is a very dangerous situation, and I have contacted Ford and they have stated there is no fix for this. I have contacted Carvana which is where I recently purchased the truck within the…

Read full complaint

Guessing the date below Truck shuts off when trying to take off and go. This has happened a few times and even pulling onto a main highway. This is a very dangerous situation, and I have contacted Ford and they have stated there is no fix for this. I have contacted Carvana which is where I recently purchased the truck within the past month and they state the recall was listed and there's nothing they can do it's up to Ford to fix a recall. They will not take the truck back and now we are stuck paying for over $30,000 on this truck and it keeps stalling on us. We cannot afford for it to just sit in our yard and pay for it if it's not running. We need help to get this fixed. We have no idea what's causing it but assuming it could have everything to do with the open recall or the battery. That battery is over $4000 if we have to replace it. Another thing we noticed is the LED lights on the headlights went out randomly and haven't come back on. Another very expensive fix for a truck we just purchased less than a month ago. We took the truck in the shop within the first few days of owning it due to a few issues we felt were not right like pulling to one side, feeling as if it were going over rutted areas on the roadways with a bump and jerk to it as well like it was a transmission issue. The insurance company with Carvana choose the place to take it to and we dropped it off and the next day they called and stated nothing was found to be wrong with it and Carvana knew we were out of return in time to replace it when they had us drop it off it was like another day.

NHTSA ODI #11711741

Mileage unknown · Jan 14, 2026
Wheels

The manufacturer is unwilling or unable to perform recall 23V896 in a timely manner. I have submitted my truck for inspection at an authorized dealer, Gullo Ford of Conroe, TX, on October 6, 2025 per manufacturer requirements. As of this writing, January 14, 2026 I have not been advised of availability of parts to remedy the def…

Read full complaint

The manufacturer is unwilling or unable to perform recall 23V896 in a timely manner. I have submitted my truck for inspection at an authorized dealer, Gullo Ford of Conroe, TX, on October 6, 2025 per manufacturer requirements. As of this writing, January 14, 2026 I have not been advised of availability of parts to remedy the defect. I am asking that necessary parts be supplied and the recall be performed in a timely manner, as soon as possible at this point.

NHTSA ODI #11710911

Mileage unknown · Jan 14, 2026
Power Train

We own a 2021 Ford F-150, that is down since the first of September, 2025, due to recall 23S65. We've been in weekly contact with our local dealer since then. They are doing everything possible to get the parts in to repair our truck, but parts are and have been on backorder, with no ETA from Ford. We have also been in contact w…

Read full complaint

We own a 2021 Ford F-150, that is down since the first of September, 2025, due to recall 23S65. We've been in weekly contact with our local dealer since then. They are doing everything possible to get the parts in to repair our truck, but parts are and have been on backorder, with no ETA from Ford. We have also been in contact with Ford customer service in Dearborn and had an open case with them. They have closed our case because they can't help and told us the local dealer is responsible, then they moved us to recall department now and no longer respond. We feel 4 months is a ridiculous amount of time on Ford's part for these parts to be on and still on backorder. We have no option for help and wondering if you could. It's has been an extremely difficult situation for us to be without our truck for this extended amount of time.

NHTSA ODI #11710827

Mileage unknown · Jan 13, 2026
Steering

September 2025, we were on a vacation when we noticed that the column gear shifter on our 2021 Ford F150 seemed a bit "loose" when shifting. No issues getting into the appropriate gear…but a weird loose feeling. My husband pulled off the leather boot on the column (not sure if this is what it is called, I believe it keeps dust …

Read full complaint

September 2025, we were on a vacation when we noticed that the column gear shifter on our 2021 Ford F150 seemed a bit "loose" when shifting. No issues getting into the appropriate gear…but a weird loose feeling. My husband pulled off the leather boot on the column (not sure if this is what it is called, I believe it keeps dust out) and found the problem. Two missing bolts! Earlier that year, I had found a bolt in the floor of the truck, and, unable to find where it came from (or did it even belong to the truck? I did not know) I put it in a ziploc bag, into the glove box. Turns out that bolt fit. So we had one bolt, and the shifting felt okay. But we still needed one bolt, so I did some internet sleuthing. I found the part (W790628S900) and ordered it, and we installed it when we got home. We theorize that the “ziploc bolt” came loose early in 2025, and the second bolt (never found) came loose on our trip. We know that up until this problem, we had never, ever, removed that dust cover, so we were not responsible for the two bolts coming loose. Components: that "failed" would be the two bolts on the column gear shifter (under the dust cover) Safety: we were very worried that without the two bolts, we would not be able to shift at some point! Confirmed: no, because we were camping on vacation, and did the troubleshooting ourselves Inspected: we will ask our mechanic when we next take the truck in Warning: no, just that we noticed that the column gear shifter was "loose" (again, likely that this was after the 2nd bolt came out).

NHTSA ODI #11710697

Mileage unknown · Jan 9, 2026
Air BagsElectrical SystemService Brakes

Started after McGee ford did a service on my truck Apparently they told ford they repaired electrical recalls which I wasn’t having issues with nor did I know They did anything! They did however erase the recalls so that was 8-2024 shortly after my truck experienced major electrical issues, another dealership told me it was gon…

Read full complaint

Started after McGee ford did a service on my truck Apparently they told ford they repaired electrical recalls which I wasn’t having issues with nor did I know They did anything! They did however erase the recalls so that was 8-2024 shortly after my truck experienced major electrical issues, another dealership told me it was gonna be 6k and 4 weeks to fix I was in awe I left with my truck that had no blinkers no air bags and so on 15 safety codes! I battled this for a year and then my parking break locked up while driving 70 on the highway! That’s the recall megee claimed they fixed I’m not rich single dad 100% of rhe time and I sure my kids everywhere daily, I do research call ford find intact i had a recalll so im thinking it will get fixed! 6 weeks later they not fixed i was told 2 days Now heritage and ford won’t fix it they want megee ford the certified service and dealer to pay for it. It’s winter im a contractor in Vermont they let me borrow a Sentra with summer tires on it. Couldn’t make it off my road. I’m still driving my kids around! I almost reck once a day as the whole system is messed up now! I feel like I’m being bullied and picked on because of my nationality

NHTSA ODI #11710040

Mileage unknown · Jan 9, 2026
Power Train

My vehicle has been with the Ford dealership for about a month and the mechanic and the engineers still have not found why my vehicle is giving a service wrench warning. When driving the vehicle will flash red warning lights which makes the vehicle unsafe to drive. I have paid for an Auxiliary Transmission Pump and battery. This…

Read full complaint

My vehicle has been with the Ford dealership for about a month and the mechanic and the engineers still have not found why my vehicle is giving a service wrench warning. When driving the vehicle will flash red warning lights which makes the vehicle unsafe to drive. I have paid for an Auxiliary Transmission Pump and battery. This did not fix my truck. The dealership said they replaced the PCM, but it didn’t fix the truck. I seen that these trucks had recalls.

NHTSA ODI #11710031

Mileage unknown · Jan 9, 2026
EngineFuel/propulsion System

Due to waiting for a recall fix for ( NHTSA #-25V455 ) My F150 Raptor has been having all listed failing issues, Miss fire at idle or when fuel is hot, issue starting on a handful of times. I have been driving it after 4 -5k miles of this and I was alerted today after replacing ( All Injectors, Coils, Spark Plugs, ETC ) That I m…

Read full complaint

Due to waiting for a recall fix for ( NHTSA #-25V455 ) My F150 Raptor has been having all listed failing issues, Miss fire at idle or when fuel is hot, issue starting on a handful of times. I have been driving it after 4 -5k miles of this and I was alerted today after replacing ( All Injectors, Coils, Spark Plugs, ETC ) That I may need a new engine. This could have caused a crash and is now costing me an entire engine due to no fix or parts availability. Thousands of Dollars for a new engine out of my pocket due to fuel starvation. Cylinder 4 Miss fire's at idle. They appeared once I returned home from the mountains back to texas with hot weather.

NHTSA ODI #11709942

Mileage unknown · Jan 9, 2026
Power Train

Please see attachment: To Whom It May Concern, I am writing to formally request NHTSA’s review and further action regarding Ford Motor Company’s handling of Safety Recall 23V‑896 and 23S-65, affecting my 2021 Ford F‑150 (F1 3509). I appreciate NHTSA’s oversight of this recall; however, based on my direct experience and the tech…

Read full complaint

Please see attachment: To Whom It May Concern, I am writing to formally request NHTSA’s review and further action regarding Ford Motor Company’s handling of Safety Recall 23V‑896 and 23S-65, affecting my 2021 Ford F‑150 (F1 3509). I appreciate NHTSA’s oversight of this recall; however, based on my direct experience and the technical information available, I believe the current remedy strategy leaves owners exposed to ongoing safety risks. My vehicle experienced fractured rear axle hub bolts, a failure mode that Ford’s defect report attributes to micro‑movement and backlash between the axle shaft splines and the wheel‑end hub splines. This movement leads to loss of clamp load, fretting wear, and ultimately bolt fatigue and fracture. The fractured bolts on my truck confirm that this failure chain had already progressed to an advanced stage. Ford performed what they describe as an interim repair, which consisted of replacing the fractured bolts and inspecting the hub and axle components. However, Ford has acknowledged that the final remedy is not yet available, and that the interim repair does not address the underlying design issue that allows spline movement and progressive wear. As a result, the same conditions that caused the initial failure may reoccur. From a mechanical and safety standpoint, replacing bolts without correcting the root cause — the loss of clamp load and resulting spline backlash — does not eliminate the defect. It merely resets the system temporarily. Ford’s own documentation confirms that the interim repair uses the same bolt design, with the same torque and elongation characteristics, and therefore the same long‑term vulnerability.

NHTSA ODI #11709836

Mileage unknown · Jan 8, 2026
Unknown Or Other

My Rear axle bolt broke in early October. It has now been over 3 months and I have zero update on when my recall will be addressed. I have a rental, but this is beyond the fair and reasonable time frame to repair a recall. The Service center can provide zero update or status of when this will be resolve. I'm making 4 payment…

Read full complaint

My Rear axle bolt broke in early October. It has now been over 3 months and I have zero update on when my recall will be addressed. I have a rental, but this is beyond the fair and reasonable time frame to repair a recall. The Service center can provide zero update or status of when this will be resolve. I'm making 4 payment on a vehicle that I don't have. What other recourses do we have. Can manufacturers just take months on end to repair when customer are without their personal or work vehicles?

NHTSA ODI #11709676

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.