NHTSA Expands Investigation into Ford EcoBoost Engines

The National Highway Traffic Safety Administration (NHTSA) has recently announced that it will be expanding its investigation into late-model Fords equipped with EcoBoost engines. What initially started as a probe into 2021 model-year Broncos equipped with 2.7-liter turbocharged engines has now evolved into a much broader look into several other models and the larger 3.0-liter EcoBoost motor.

The investigation was prompted last summer when nearly 30 complaints were issued about the 2.7-liter motor cutting out at highway speeds in Ford Broncos. This led to petitions demanding action, and the NHTSA launched a formal investigation. Regulators were concerned about the possibility of “catastrophic engine failure” due to a presumed defect with the intake valves.

While the investigation has been ongoing, it has expanded to include other models and Ford’s larger 3.0-liter turbo used widely in its lineup. The NHTSA Office of Defects Investigation upgraded the investigation to include an engineering analysis of the 2021-2022 Ford Bronco, Edge, Explorer, and F-150, as well as the 2021-2022 Lincoln Aviator and Nautilus, all equipped with either the 2.7 or 3.0-liter EcoBoost.

According to the NHTSA, there have been 328 customer complaints and 487 warranty claims relating to the vehicles under investigation. However, no injuries have been associated with any of these incidents. This brings the total number of vehicles being looked into from roughly 25,000 to a staggering 708,000.

Ford has informed the NHTSA that the defective valves were manufactured out of an alloy known as “Silchrome Lite,” which can become “excessively hard and brittle if an over-temperature condition occurs during machining of the component.” The company also stated that a design change in October 2021 switched the intake valve material to a different alloy. Ford believes that “defective intake valves commonly fail early in a vehicle’s life and has suggested that the majority of failures have already occurred.”

It appears that cheaper materials were used on the alloy intake valves, which did not work out as intended. While exhaust valves can withstand higher temperatures, automakers sometimes opt for less robust materials on the intake side to reduce manufacturing costs. However, this decision can lead to underperforming parts and potential issues down the line.

The NHTSA stated that a fractured intake valve can result in catastrophic engine failure and a loss of motive power, often requiring a full engine replacement. This is a setback for Ford, which has been working to improve its reputation for reliability. The frequency of recalls has increased across the industry in recent years, and Ford has been eager to distance itself from any negative associations.

It is likely that this investigation will eventually lead to a formal or voluntary recall. While repairing the alleged defect will be costly for Ford, leaving it unaddressed may result in more broken valves and the need for engine replacements. This would only further damage consumer confidence in Ford’s products and prove more costly in the long run.

In conclusion, the NHTSA’s expanded investigation into Ford EcoBoost engines is a significant development for both the automaker and consumers. It highlights the importance of thorough quality control and the potential consequences of using subpar materials. Ford will need to address these issues promptly to maintain its reputation and ensure customer satisfaction.