2021 Ford E-450

The Office of Defects Investigation (ODI) opened Recall Query (RQ) 24003 on February 27, 2024, to evaluate the scope and remedy effectiveness of NHTSA recall 24V097. On February 16, 2022, Ford Motor Company (Ford) issued a safety recall, NHTSA recall 22V089, for certain 2021-2022 Ford E-350 and E-450 vehicles equipped with dual rear wheels. According to the filing, specific hydraulic lines could leak resulting in a sudden loss of power steering and power brake assist, increasing the risk of a crash. The remedy involved a dealer inspection of the lines and their replacement as necessary. Only vehicles that failed the inspection received updated parts. On February 9, 2024, Ford issued a new recall, NHTSA recall 24V097, to replace the specific hydraulic lines on any vehicle that had not yet been inspected and on any vehicle which had passed inspection within the previous twelve months. However, vehicles which had passed the inspection more than twelve months ago would not be included within the scope of the new recall, as Ford deemed them to have a low likelihood of failure. ODI opened this RQ to better understand Ford's scoping of recall 24V097, specifically concerning the inspected-only vehicles not included in the new recall filing. ODI sent Ford an information request letter on April 18, 2024. Ford responded, in full, on May 31, 2024. ODI reviewed Ford's data which showed that the vehicles not included in the new recall had a predicted failure rate of less than 0.25% within 10 years from the date of inspection. By comparison, the vehicles included in the new filing have had a failure rate of approximately 2% prior to being recalled again. ODI analysis of complaint and warranty data further supports Ford's assessment that vehicles that passed inspection more than twelve months prior to recall 24V097 are unlikely to experience the defect condition. ODI is closing this RQ without a manufacturer action. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

Airbag module casing is cracked.

NHTSA ID

11709041

Incident

Jan 2, 2026

Engine camshaft and lifters failed. Truck is at a Ford dealer. Engine could fail in the middle of the road, causing an accident. This is our eighth vehicle with the same issue taken to a ford dealer in the past year. A little knocking noise started that quickly turned into a loud knocking/rattling noise. No lights came on the truck.

NHTSA ID

11688895

Incident

Sep 3, 2025

See attached document for complaint.

NHTSA ID

11644752

Incident

Feb 12, 2025

This is one of 4 of my 2021 ford econoline fleet vehicles purchased in 2021 that have had engine failure. I am one of many contractors in my area and others around the country who have had this issue with the same F59 engine. Ford has failed to issue a recall.

NHTSA ID

11643146

Incident

Jan 13, 2025

Engine Camshaft and lifters failed, unit was inspected by ford dealer and engine had to be replaced. Engine can stop working and truck could break down in the middle of the road. No warning lamps, just a loud knocking sound when brakes were applied and truck was downshifting to stop. A lot of other people that purchased these ford light duty trucks with the 7.3L engine are having the same issue.

NHTSA ID

11640826

Incident

Nov 25, 2024

Engine camshaft and lifters failed and were inspected by Ford dealer, which corrected the issue by replacing the engine. Engine can failed and truck get stuck in the middle of the road. In the past 6 months its our 4th Ford truck with the same issue and a lot of other Fedex contractors that purchased a Ford truck with the 7.3L engine are reporting the same issue. No warning light was on in this vehicle, just started with a knocking sound that got worse until it got to the dealer and engine had to be replaced

NHTSA ID

11640804

Incident

Oct 3, 2024

The contact owns a 2021 Ford E-450. The contact stated while parking the vehicle, the steering wheel and brake pedal became stiff, and the vehicle failed to slow down as intended. The contact stated that the brake pedal was continuously depressed for the vehicle to come to a stop. The vehicle was towed to an independent mechanic where it was diagnosed that the power steering hose and fluids needed to be flushed and refilled. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 14,104.

NHTSA ID

11603091

Incident

Jul 7, 2024

Mileage

14,104 mi

Component= Traction control and cruise control. Safety risk=Driving a Ford e-450 Class C RV on interstate at 63 MPH going generally up hill with cruise control on, the "Service AdvanceTrac" warning light came on dashboard. I Immediately lost cruise control capability and steering became a little shakey. Pulled into rest area shut vehicle off. A few minutes and started again. Error went away and cruise control was functioning. Happened again a few hours later and I did the same thing and continued on. What happened=As I was driving, the " Service Advance Traction" light came on and the cruise control stopped, my class c rv immediately slowed at a high rate, a semi was behind me trying to get over to the middle lane. When I slowed down suddenly due to the cruise control going out, the semi had no choice but to change lanes quickly missing the back of my vehicle by a foot or so. If he was not alert as to what was happening, I most assuredly would not be typing this letter. It was that close!! Note= This also happened last year as we only take the RV out a few weeks out of the year. I brought it to Klammer Ford in New Port Richey F1l immediately after we got back from the last trip. They could not reproduce issue or find anything wrong Lamps= The only warning light that came on was a "Service Advance traction" light. No prior indication of any kind.

NHTSA ID

11594828

Incident

Jun 10, 2024

This article supersedes TSB 25-2572 to update the Parts List to correct the part number LC3Z-6006-L to LC3Z-6781-A, remove the flex plate bolts AL3Z-6379-BA from the parts list as these bolts are in kit LC3Z-6781-A, update the claim quantity of the part number W709771-S440 to 9 pieces (F-650/F750-Engine Replacement), W706447-S437 and W715068-S437 to 4 pieces, W712861-S439 to 8 pieces(F-Super Duty Pickup And Chassis Cab-Engine Replacement) / 8 pieces (F-53 Motorhome/F-59 Stripped Chassis Cab/F-650,F750 Engine Replacement) / W714286-S442 to 4 pieces (F-Super Duty Pickup And Chassis Cab-Camshaft and Tappet Repair / F-Super Duty Pickup And Chassis Cab-Engine Replacement), include LC3Z-6020-A for the Engine replacement lists, include 1 fuel injector seal kit to the Camshaft and Tappet repair lists, include 4 pieces of W520114-S440 to the E Series-Camshaft and Tappet Repair list, and update the engine oil part numbers XO-5W30-Q1SP and CXO-5W30-LSP6. Some of the vehicles listed in the Model statement above may exhibit an upper engine ticking or tapping noise at idle. Customers may also report experiencing ro

Ford and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory wireless keyless entry keypad systems may or may not come with a wallet card containing the master code. Unlike the integrated wired keypad, the accessory wireless keypad master code cannot be retrieved from the vehicle using a diagnostic scan tool or from the label printed on the body control module (BCM). The Factory Keyless Entry Code application within the diagnostic scan tool will not provide an applicable master code for the accessory wireless keypad. If the wallet card for an accessory keypad is not available, the "Wireless RF Keypad Diagnosis Guide" can be referenced and provides direction on how to retrieve the master code. This guide is located under the Workshop Manual tab > Accessories > Installation > Wireless RF Keypad Diagnosis Guide > PPT C > Step C2.<br /><br /> Note: The only available keypad for some vehicles from the assembly plant is the accessory wireless keyless entry keypad. The integrated wired keypad cannot be installed on vehicles not equipped from the factory with a wired keyless entry k

This article supersedes TSB 25-2322 to update the Service Procedure, Labor Operations and Parts List. Some of the vehicles listed in the Model statement above may exhibit an upper engine ticking or tapping noise at idle. Customers may also report experiencing rough engine performance, engine misfire, or a malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0301-P0308 in the powertrain control module (PCM). This may be due to camshaft and/or valve tappet having excess wear within the engine assembly.

This is a proactive investigation program by Ford Motor Company to inspect a limited number of affected vehicles that are customer-owned. Ford is voluntarily conducting this program to evaluate the software currently installed on one or more electronic modules in the affected vehicles.

Some 2021-2025 Expedition/Navigator/F-150/F-Super Duty/F-53 Motorhome/F59 Commercial Stripped Chassis/F-650/F-750/Transit vehicles equipped with a 2.7L/3.5L (non hybrid)/6.8L/7.3L engine and 2021-2026 E-Series may exhibit a rattle/scraping noise from the bellhousing area on start-up. Workshop Manual (WSM), Section 303-00 Engine System - General Information > Diagnosis and Testing and 303-06 > Starting System has been updated to address this condition. Additionally, WSM, Section 303-01 > Removal and Installation > Engine to Transmission Spacer Plate has been added to address this condition. Refer to the revised WSM sections for normal diagnosis.

Some 2021-2025 F-150 vehicles equipped with a 5.0L/5.2L engine, 2021-2025 F-Super Duty/F-53 Motorhome/F59 Commercial Stripped Chassis vehicles equipped with a 6.8L/7.3L engine and 2021-2026 E-Series/F-650/F-750 vehicles equipped with a 7.3L engine may exhibit a rattle/scraping noise upon startup that may remain after the engine is running. This may be due to the starter motor drive gear not retracting after starting. To correct this condition, inspect the starter motor drive gear and shaft. If the starter motor drive gear slides back and forth by hand and/or shows signs of scoring or damage, replace the starter motor following Workshop Manual (WSM), Section 303-06 Starting System > Removal and Installation > Starter.