2021 Ford Edge

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.

My 2021 Ford Edge is experiencing a severe transmission defect. When accelerating between 22 mph and 35 mph, the vehicle hesitates, stumbles, and shudders violently (transmission shudder). The transmission struggles to engage gears properly, causing unexpected jerking and a sudden loss of acceleration power. This behavior creates a dangerous driving hazard when merging into traffic or changing lanes. This issue is consistent with Ford's Technical Service Bulletin (TSB 21-2092) regarding the 8F35 8-speed automatic transmission.

NHTSA ID

11756564

Incident

Jul 17, 2026

When driving at lower speeds the car jerks/misses. A local Ford dealership confirmed it's the torque converter. Even purchased a warranty that is suppose to cover the issue and even they are being difficult about wanting to fix it!

NHTSA ID

11755111

Incident

Jul 21, 2026

There should be a recall on the sunvisors. Because it is a safety issue, because when the Sun is in your face and you can't see driving it can very well cause an accident or getting a ticket for not being able to see your speed that you're going, because you're so far up trying to get the Sun out of your face. You can't see any of the controls or your dashboard.. That is a safety hazard. My driver's side one is broken. I can't use it at all and I'm not paying $200 to get it fixed. That's insane on top of that.My passenger side is one is starting to break as well. Also, my car is very sluggish. When i'm driving, it is sluggish back and forth like it doesn't get good acceleration.There should be a recall for that.As well. I've also noticed when I'm stopped at a light, and I slowly let off the brake the car start to jump.

NHTSA ID

11754925

Incident

Jul 23, 2026

Torque converter needs a replacing

NHTSA ID

11754270

Incident

Jul 1, 2026

The contact owns a 2021 Ford Edge. The contact received notification of NHTSA Campaign Number: 24V635000 (Engine and Engine Cooling). The local dealer was contacted, and the contact was informed that the recall repair was performed remotely. The contact stated that the dealer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11753567

Incident

Jul 29, 2026

Purge valve is sticking open when fueling making it to where it take 10 plus minutes to start car after fueling. Worried it will end up causing more issues and possibly cause problems with fuel tank

NHTSA ID

11752306

Incident

Mar 15, 2026

Transmission has gone out after only having the vehicle for 2.5 years. It will cost $10,000 to repair and that is not feasible or right. The mileage is at 74,000 but the warranty expired at 60,000. Ford should be held accountable for building these vehicles with awful transmissions.

NHTSA ID

11750391

Incident

Jul 14, 2026

The contact owns a 2021 Ford Edge. The contact stated that while driving on several occasions and making a turn, there was an abnormal clicking sound coming from underneath the vehicle. The contact added that her husband did donuts continuously and observed the sound. The vehicle was taken to an independent mechanic, where it was determined that the sound in the rear axle was coming from the left rear differential. The mechanic stated that the rear differential fluid had been leaking oil for a while and that the rear differential needed to be replaced. The vehicle was not repaired. The contact associated the failure with Manufacturer Recall: 21S02. The manufacturer was notified of the failure. The failure mileage was approximately 68,000.

NHTSA ID

11749560

Incident

Jun 8, 2026

Mileage

68,000 mi

Some 2021-2026 Ford/Lincoln vehicles may exhibit various symptoms including but not limited to the auto start/stop system not operating as intended with a "Check Charging System" message in the instrument panel cluster (IPC) while the charging system is operating properly with no charging related diagnostic trouble codes (DTC) stored. This may be due to someone using an aftermarket programmer to change the body control module (BCM) configuration to disable the auto start/stop system or perform other unsupported programming modifications. To correct this condition on F-150 and Bronco vehicles, download and run the Ford Diagnosis and Repair System (FDRS) application titled "BCM-Charging System Configuration Correction". Running this application will determine if the BCM configuration was modified by the customer and if so, provide the option to return the configuration back to factory settings. For other vehicle models exhibiting concerns related to unsupported aftermarket BCM programming, submit a Technical Support Request (TSR) requesting support to revert the BCM configuration

This bulletin supersedes 26-2171. Reasons for update: update the Parts list to add a note to clarify the application of the part numbers W520102-S442 and 4S4Z-3N324-AA "FWD Only". Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder condition, most noticeable at speeds below 60 mph (100 km/h)  No relevant diagnostic trouble codes (DTC) present  Traceable shudder event with IDS/FDRS reading *(Figure 1)* This condition may be perceived/felt as an engine misfire. This may be due to a concern with the output planetary assembly.

Some 2021-2024 Ford and Lincoln vehicles may exhibit an "Updating SYNC" message on the vehicle center display screen after an over the air (OTA) update. The message can be cleared from the center display screen and SYNC can be used normally, but it will re-appear at every subsequent ignition cycle. Inform customers that engineering is currently working on a software update solution for this condition to be delivered OTA expected in late Q3 2026. Software will update automatically if vehicle connectivity is enabled in the vehicles settings. Monitor Professional Technician System (PTS) for additional information.

This bulletin supersedes 26-2194. Reason for update: update the Parts list to correct a part description " Loctite 638", update the claim quantity for the drain/fill plug, update the claim quantity of the wheel hub bolts (Corsair) and limited the parts list for Edge/Nautilus to only the rear drive unit fluid. Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder chatter condition, most noticeable at low speeds turning  No relevant diagnostic trouble codes (DTCs) present This may be due to internal rear drive unit (RDU) fluid contamination.

Some of the vehicles listed in the model statement above equipped with SYNC4 may experience a blank center display screen or black center display after welcome animation. The rear-view camera will still function when shifting the vehicle to reverse under these conditions.

Quality improvements include: - Enhanced system performance, disk usage limits and memory monitoring