NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
45 reportsMileage unknown · Dec 20, 2025
EngineFuel/propulsion System
On July 25, 2025 my 2022 Lincoln Aviator Hybrid Grand Touring Edition stalled while driving on Interstate 25 in Colorado Springs. I lost partial control of the vehicle but was able to guide it onto the shoulder and allow it to coast to a stop. I had this vehicle towed to the dealership (where it was purchased new): Phil Long Li…
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On July 25, 2025 my 2022 Lincoln Aviator Hybrid Grand Touring Edition stalled while driving on Interstate 25 in Colorado Springs. I lost partial control of the vehicle but was able to guide it onto the shoulder and allow it to coast to a stop. I had this vehicle towed to the dealership (where it was purchased new): Phil Long Lincoln, Motor City in Colorado Springs, Colorado. It has been there ever since (almost 5 months) and has not been repaired. The service department suspects that the current safety recall issued July 8, 2025 (NHTSA Recall number: 25V455) was the root cause. They claim they could find nothing in the logs but they cannot rule out this as a problem. This is a life threatening issue with this vehicle and I have also been without my car for almost 5 months with repair available or capable by the dealer or Lincoln. This a very unreasonable amount of time and has been an undue burden upon me. I have sought to get a vehicle buy back under both the Lemon Law and the duration of this safety recall and they have refused (Lincoln corporate and the dealership). Please help.
NHTSA ODI #11706296
Mileage unknown · Dec 15, 2025
Structure
Rear door trim came loose and fell off while driving. Had the service department at the local dealership look at the missing trim on the rear of the car and they noticed multiple of the plastic clips holding the trim on the rear were broken and remained in the area where the trim was attached.
NHTSA ODI #11705135
Mileage unknown · Nov 7, 2025
Electrical SystemEngineFuel/propulsion System
high voltage alert and vehicle shuts down and unable to drive and car locks up Should be recall# 23s53 and NHTSA campaign # 23v-626 It has not been repaired yet and this is very frustrating has happened 4-5 times Last incident happened on 11/7/2025 inside of a car wash & had to get towed
NHTSA ODI #11698286
3,333 miles · Oct 16, 2025
Structure
The contact owns a 2022 Lincoln Aviator. The contact stated that while driving at 30 MPH, the trim pieces on the liftgate partially detached. A dealer was contacted. The vehicle was not taken to a dealer or independent mechanic to be diagnosed; however, the vehicle received an unknown recall repair and was provided an estimate f…
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The contact owns a 2022 Lincoln Aviator. The contact stated that while driving at 30 MPH, the trim pieces on the liftgate partially detached. A dealer was contacted. The vehicle was not taken to a dealer or independent mechanic to be diagnosed; however, the vehicle received an unknown recall repair and was provided an estimate for the repair. The vehicle was not yet repaired. The manufacturer was not notified of the failure. The failure mileage was 3,333.
NHTSA ODI #11693917
Mileage unknown · Oct 6, 2025
Electrical SystemExterior LightingService Brakes
1- ABS/Braking Issue The ABS system appears to be malfunctioning. On multiple occasions, typically once or twice a week, when I apply the brakes, the tires lock up and cause the vehicle to skid. This happens most often when descending hills or backing up on a sloped driveway. The wheels lock and slide until I release the brake p…
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1- ABS/Braking Issue The ABS system appears to be malfunctioning. On multiple occasions, typically once or twice a week, when I apply the brakes, the tires lock up and cause the vehicle to skid. This happens most often when descending hills or backing up on a sloped driveway. The wheels lock and slide until I release the brake pedal, posing a serious safety concern. 2- Severe Water Leak Interior Roof Area There is a significant water leak from the interior roof, specifically from the top center area near the rearview mirror, every time it rains. I’ve taken the vehicle to the dealer multiple times. They confirmed that all drain tubes are clear, all seals are functioning properly, and no water appears to be entering from the sliding moonroof. However, the issue persists. Water pours down like a waterfall through the vent (as shown in the attached photo), soaking the center console and creating an unsafe driving condition. I have also recorded videos showing the water intrusion. Living in Guam, where it rains frequently, this has become a major problem. 3- Malfunctioning Interior Ceiling Light The ceiling light on the driver's side (center dome light) turns on randomly and often remains on until manually switched off. The dealer has inspected this issue but reported no faults found. Despite this, the problem continues to occur intermittently. 4- Rear Camera Display Issue When shifting into reverse, the monitor occasionally turns completely blue, and the backup camera does not function. The blue screen remains until the vehicle is turned off and restarted. This happens sporadically and disrupts safe maneuvering.
NHTSA ODI #11691739
Mileage unknown · Oct 3, 2025
Air BagsElectrical SystemStructure
Emergency escape issue Like many modern cars the aviator was designed with electric opening doors. Of the four doors, only the front driver side door has a manual override in case of emergency. That means if a major accident was to occur on that ONE door and disable the vehicle the other 3 doors do not have a way to exit. Wh…
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Emergency escape issue Like many modern cars the aviator was designed with electric opening doors. Of the four doors, only the front driver side door has a manual override in case of emergency. That means if a major accident was to occur on that ONE door and disable the vehicle the other 3 doors do not have a way to exit. Why would the nhtsa allow a vehicle on a road that at a minimum doesn't have a override for left side and right side or more than one door?
NHTSA ODI #11691190
10,000 miles · Oct 2, 2025
Fuel System, Gasoline
The contact owns a 2022 Lincoln Aviator. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated while driving approximately 50 MPH, the vehicle stalled. The contact was unable to pull over to the side of th…
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The contact owns a 2022 Lincoln Aviator. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated while driving approximately 50 MPH, the vehicle stalled. The contact was unable to pull over to the side of the road. It was unknown whether a warning light was illuminated. The vehicle failed to restart and was towed to the residence. The dealer was contacted and confirmed that the part for the recall repair was not yet available. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 10,000.
NHTSA ODI #11690950
Mileage unknown · Sep 19, 2025
Unknown Or OtherVisibility/wiper
Reference my NHTSA complaint # 11681607 dtd 8/19/25 regarding the problem with Autosense wipers that I’ve had since I bought my Aviator 2.5 yrs ago. As I previously reported, problem was finally resolved in April when dealer replaced the Autosense sensor. I have come to learn that the plastic covering dealer found on the sensor …
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Reference my NHTSA complaint # 11681607 dtd 8/19/25 regarding the problem with Autosense wipers that I’ve had since I bought my Aviator 2.5 yrs ago. As I previously reported, problem was finally resolved in April when dealer replaced the Autosense sensor. I have come to learn that the plastic covering dealer found on the sensor (see attached pic) is actually a protective film for part shipment & should have been removed by the assembly plant prior to installing the sensor but was NOT. There are other owners that have this same ‘wipers gone wild’ condition with Autosense wiping in which the windshield does not clear enough for safe driving & you need to switch to manual wiper operation to clear the windshield. This plant assembly error should trigger a recall with all manufacturers that use this part, not just Lincoln.
NHTSA ODI #11688314
Mileage unknown · Sep 19, 2025
Electrical SystemUnknown Or OtherInjury
My Aviator was parked with trunk open to load groceries from shopping cart. Must have stepped under bumper such that it triggered the kick sensor to close the tailgate. The problem is, it did NOT detect spouse’s body, did NOT stop the tailgate from closing & as a result, hit him on the head. He jolted out of the way & the tailga…
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My Aviator was parked with trunk open to load groceries from shopping cart. Must have stepped under bumper such that it triggered the kick sensor to close the tailgate. The problem is, it did NOT detect spouse’s body, did NOT stop the tailgate from closing & as a result, hit him on the head. He jolted out of the way & the tailgate continued to close all the way. This is serious safety issue!
NHTSA ODI #11688306
Mileage unknown · Aug 19, 2025
Visibility/wiper
The AUTOSENSE wiper function has been erratic & not working properly since my Aviator was a yr old (2022). None of the Autosense wiper stalk positions worked correctly to clear the windshield enough for safe visability. I had dealer check this problem 3 times in 2023 & 2024 & they indicated no problem was found & no codes appea…
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The AUTOSENSE wiper function has been erratic & not working properly since my Aviator was a yr old (2022). None of the Autosense wiper stalk positions worked correctly to clear the windshield enough for safe visability. I had dealer check this problem 3 times in 2023 & 2024 & they indicated no problem was found & no codes appeared. After experiencing dangerous visability issues on a 4 hr trip in which I needed to keep the regular wiper on to see (because Autosense didn’t clear windshield enough to see on Hwy), I left vehicle at dealer & refused to pick it up until problem was corrected once & for all. Since car is under warranty they decided to replace the sensor & found it to be defective (yellowed). Since replacing the sensor Autosense now works. This leads me to believe these sensors are failing prematurely. I’m posting this in case others are experiencing a similar problem with Autosense wipe.
NHTSA ODI #11681607
Official recalls
21Jul 14, 2026
Ford Motor Company (Ford) is recalling certain 2020-2027 Aviator and 2020-2026 Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, tipping, or sliding unexpectedly.
Consequence & remedy
Consequence: A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing the risk of injury.
Remedy: Dealers will inspect and replace the bezel around the switch as necessary, 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 explaining the safety risk were mailed August 19, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Lincoln Aviator owner notification letters were mailed August 21, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S52. This recall expands Recall 25V393. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.
Mar 17, 2026
Ford Motor Company (Ford) is recalling certain 2020-2026 Explorer and Lincoln Aviator vehicles. The seat belt anchor bolts at the second-row outer seating positions may be improperly secured.
Consequence & remedy
Consequence: A loose seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.
Remedy: Dealers will inspect the second-row outer seat belt lower anchor bolts and replace or repair them as necessary, free of charge. Owner notification letters were mailed March 30, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C18. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 19, 2026.
Mar 3, 2026
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer, Escape, Lincoln Aviator, and Lincoln Corsair vehicles. The windshield wiper motor may fail and prevent the windshield wipers from operating properly.
Consequence & remedy
Consequence: Windshield wipers that fail to operate properly can reduce visibility, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the front wiper motors as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed April 2, 2026. Additional letters will be sent once the final remedy is available, anticipated in October 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S14. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 4, 2026.
Mar 3, 2026
Ford Motor Company (Ford) is recalling certain 2020-2022 Escape, Lincoln Corsair, 2020-2024 Lincoln Aviator, and Explorer vehicles. The image on the center display may flip or invert, resulting in an incorrectly displayed rearview image when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
Consequence & remedy
Consequence: An incorrectly displayed rearview image can reduce the driver’s view behind the vehicle, increasing the risk of a crash.
Remedy: Dealers will update the accessory protocol interface module (APIM) software, free of charge. Owner notification letters were mailed June 23, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C11. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 5, 2026.
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.
Jun 27, 2025
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
Consequence & remedy
Consequence: A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.
Remedy: Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.
Jun 13, 2025
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator, and Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, folding, or sliding unexpectedly while driving.
Consequence & remedy
Consequence: A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing their risk of injury.
Remedy: Dealers will inspect the second-row seat switch, and replace the bezel around the switch as necessary, free of charge. Owner notification letters were mailed August 7, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S67.
Jun 13, 2025
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator vehicles. The rear door window bars and C-pillar trim may have insufficient adhesive bonding, which can allow the trim to detach from the vehicle.
Consequence & remedy
Consequence: Detached trim may cause a road hazard and increase the risk of a crash.
Remedy: Dealers will repair or replace C-pillar appliques and window division bars, free of charge. Owner notification letters were mailed September 29, 2025. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 25S66.
May 23, 2025
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator and Lincoln Corsair vehicles equipped with a Revel Audio System that were repaired incorrectly under recall 22V-953. When the driver's seat belt is not buckled and the vehicle is started, the seat belt warning system may activate the audible warning chime for an insufficient amount of time of less than 4 seconds. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Consequence & remedy
Consequence: An audible warning chime that does not properly alert of an unbelted seat belt can increase the risk of injury during a crash.
Remedy: Dealers will update the audio control module software, 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 25C18.
Mar 14, 2025
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles previously repaired incorrectly under recall number 23V-342. The video output may fail, preventing the rearview camera image from displaying.
Consequence & remedy
Consequence: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Remedy: Dealers will update the Image Processing Module software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S27.
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.
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.
May 24, 2024
Ford Motor Company (Ford) is recalling certain 2020-2024 Lincoln Aviator vehicles. The accessory protocol image module (APIM) can be affected by electromagnetic interference with a cell phone in the vehicle, causing the rearview camera image to flicker or become distorted.
Consequence & remedy
Consequence: A flickering or distorted rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Remedy: Owners are advised not to use their cell phones while reversing until the remedy is completed. Dealers will install shielding on the accessory protocol image module (APIM), free of charge. Owner notification letters were mailed on October 23, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S35.
Sep 8, 2023
Ford Motor Company (Ford) is recalling certain 2020-2022 Lincoln Aviator and Ford Explorer vehicles equipped with 3.0L PHEV engines. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.
Consequence & remedy
Consequence: Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
Remedy: Dealers will perform a Battery Energy Control Module (BECM) diagnostic test and replace the high voltage battery pack, as necessary, free of charge. Owner notification letters were mailed on April 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford Motor Company's number for this recall is 23S53.
Aug 25, 2023
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator, 2018-2021 Lincoln Navigator, 2022-2023 Ford Transit, and 2021 Ford Bronco vehicles. The rearview camera, or 360-degree view camera if equipped, may not display a rearview image when the vehicle is placed in reverse.
Consequence & remedy
Consequence: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Remedy: Dealers will replace the rearview camera, and update the software and wiring as necessary, free of charge. Owner notification letters were mailed November 20, 2023 to Lincoln owners. Ford vehicle owners notification letters were mailed March 4, 2024. Ford remedy parts are anticipated 2nd Quarter 2024. Ford's number for this recall is 23S48.
May 12, 2023
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
Consequence & remedy
Consequence: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Remedy: Dealers will replace the 360-degree camera, free of charge. Owner notification letters were mailed November 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S23. This recall expands and replaces NHTSA recall number 23V-022. Vehicles previously repaired under 23V-022 will need to have the new remedy performed.
Jan 23, 2023
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
Consequence & remedy
Consequence: Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
Remedy: Dealers will update the image processing module (IPMB) software, free of charge. Interim owner notification letters informing owners of the safety risk were mailed April 25, 2023. Owner notification letters were mailed February 13, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S02. This recall expands and replaces NHTSA recall number 21V-735. Vehicles previously repaired under 21V-735 will need to have the new remedy performed.
Dec 23, 2022
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator and 2020-2022 Lincoln Corsair vehicles equipped with a Revel Audio System. When the driver's seat belt is not buckled and the vehicle is started, the seat belt warning system may activate the audible warning chime for an insufficient amount of time of less than 4 seconds. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Consequence & remedy
Consequence: An audible warning chime that does not properly alert of an unbelted seat belt can increase the risk of injury during a crash.
Remedy: Dealers will update the audio control module software, free of charge. Owner notification letters were mailed February 7, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C35.
Jun 24, 2022
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator and Ford Explorer vehicles. The engine rails may have been improperly heat-treated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, "Occupant Crash Protection" and 301, "Fuel System Integrity."
Consequence & remedy
Consequence: Improperly heat-treated engine rails may reduce the vehicle's structural protection in a crash, increasing the risk of injury. In addition, an engine rail may detach and contact the road while driving, increasing the risk of a crash.
Remedy: Dealers will perform an engine rail strength test and replace the rails as necessary, free of charge. If the engine rails require replacement, owners will have the option for a vehicle replacement or buyback. Owner notification letters were mailed August 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C13.
Additional source detail variants (2)
Engine
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator and Ford Explorer vehicles. The engine rails may have been improperly heat-treated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, "Occupant Crash Protection" and 301, "Fuel System Integrity."
Consequence: Improperly heat-treated engine rails may reduce the vehicle's structural protection in a crash, increasing the risk of injury. In addition, an engine rail may detach and contact the road while driving, increasing the risk of a crash.
Remedy: Dealers will perform an engine rail strength test and replace the rails as necessary, free of charge. If the engine rails require replacement, owners will have the option for a vehicle replacement or buyback. Owner notification letters were mailed August 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C13.
Structure:frame And Members
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator and Ford Explorer vehicles. The engine rails may have been improperly heat-treated. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 208, "Occupant Crash Protection" and 301, "Fuel System Integrity."
Consequence: Improperly heat-treated engine rails may reduce the vehicle's structural protection in a crash, increasing the risk of injury. In addition, an engine rail may detach and contact the road while driving, increasing the risk of a crash.
Remedy: Dealers will perform an engine rail strength test and replace the rails as necessary, free of charge. If the engine rails require replacement, owners will have the option for a vehicle replacement or buyback. Owner notification letters were mailed August 22, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C13.
Apr 14, 2022
Ford Motor Company (Ford) is recalling certain 2022 Lincoln Aviator vehicles. The front-row driver and passenger seat power head restraint cushion may detach from the head restraint assembly when adjusted to the full forward position.
Consequence & remedy
Consequence: A detached head restraint cushion can increase the risk of injury during a crash.
Remedy: Dealers will replace the front-row passenger and driver head restraints, free of charge. Interim owner notification letters to notify owners of the safety risk were mailed May 11, 2022. Owner notification letters were mailed July 29, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22S23.
Feb 16, 2022
Ford Motor Company (Ford) is recalling certain 2022 Explorer and Lincoln Aviator vehicles. The fuel filler tube may detach during a crash. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 301, "Fuel System Integrity."
Consequence & remedy
Consequence: A detached fuel filler tube can result in a fuel leak, increasing the risk of a fire.
Remedy: Dealers will install a fuel vapor line redundant locking clip, free of charge. Owner notification letters were mailed on April 4, 2022. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C02.
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
1EA23002 · 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.
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