2021 Ford F-150

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.

Daytime Running Light failure in headlight assembly. Second time it occurred. Had the first headlight assembly replaced while under warranty. I am now outside of the warranty mileage and the other side's headlight DRL has failed.

NHTSA ID

11756461

Incident

Jun 4, 2026

I've noticed that the vehicle struggle when acceleration, specially at full stop (stoplight and intersection). Feels like the engine is going to die out if I step on gas pedal.

NHTSA ID

11756394

Incident

Aug 5, 2026

The contact's son owns a 2021 Ford F-150. The contact stated that while the vehicle was parked, the owner attempted to start the vehicle; however, the vehicle failed to start. The owner replaced the battery, and the vehicle was towed to the dealer and was diagnosed with a fuel pump failure. The contact was informed that the fuel pump needed to be replaced. The contact was informed that parts were unavailable for the repair. Additionally, the owner was informed that the repair could be paid for out-of-pocket and a request for reimbursement could be made when parts became available. The owner declined to pay out of pocket for the repair. The vehicle was not repaired. The dealer requested that the vehicle be removed from the dealer lot. The vehicle was towed to an alternative dealer for storage because the vehicle was inoperable. The owner then received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was unavailable. The manufacturer was made aware of the failure, and two cases were filed. The failure mileage was approximately 66,000.

NHTSA ID

11756319

Incident

Jun 16, 2026

Mileage

66,000 mi

Left side headlight went dark. Started dimming now is full out

NHTSA ID

11756213

Incident

Jul 16, 2026

The contact owns a 2021 Ford F-150. 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 local dealer was contacted, and it was confirmed that the part was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11756188

Incident

Aug 11, 2026

i have had this at the dealer for the recall 4 months with no fix insight

NHTSA ID

11756172

Incident

Mar 3, 2026

My F150 10R80 transmission is throwing a P076F code. And the shifting has become very harsh and eratic all across the 10 gears. Hesitations, high revs, hard shifts, etc. This is a known issue by Ford and they have issued TSBs on the issue. They acknowledge that it is a design flaw within the transmission and have issued fixes. But if you are outside of the 60,000mi warranty, the burden of the costs falls on me, the owner. $9400 to replace the transmission with a new Ford transmission here in Colorado. This is a known problem in the design but Ford is not stepping up to help. They let the burden fall on the owner.

NHTSA ID

11756162

Incident

Aug 10, 2026

The contact's son owns a 2021 Ford F-150. The contact stated that after her son shifted from park(P) to drive(D), the vehicle failed to respond as needed. Several unknown warning lights were illuminated. The contact's son was able to drive to the residence nearby after several attempts. While at the residence, the failure recurred after shifting to drive(D), and the vehicle made an abnormal grinding sound. The vehicle was towed to an independent mechanic, and it was determined that the passenger’s side rear axle was fractured. The failure was associated with NHTSA Campaign Number: 23V896000 (Power Train). The vehicle was towed to a dealer, where the diagnosis was confirmed; however, parts were unavailable for the recall repair. The vehicle remained unrepaired, and no rental vehicle was provided. The manufacturer was notified of the failure, and a case was filed. The failure mileage was approximately 100,650.

NHTSA ID

11756152

Incident

Jul 29, 2026

Mileage

100,650 mi

Some 2021-2023 F-150 vehicles equipped with a 3.5L PowerBoost engine, 2020-2026 Explorer vehicles equipped with a 3.3L hybrid engine, and 2020-2023 Lincoln Aviator vehicles equipped with a 3.0L EcoBoost hybrid engine may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble code (DTC) P0A1E stored in the powertrain control module (PCM). The vehicle may be unable to enter electric-only drive modes as expected during normal drive cycles. This may be due to the belt integrated starter generator (BISG). For vehicles with this condition, follow the necessary Pinpoint Test in Workshop Manual (WSM), Section 303-06 for DTC P0A1E and repair the vehicle as directed. Note that previous replacement of the BISG does not negate the need for subsequent BISG replacements if directed to do so by the appropriate Pinpoint Test diagnostics. Engineering is investigating this BISG quality concern. Monitor PTS for updates regarding this investigation.

Customer Satisfaction Program 25M01 Certain 2021 Model Year F-150 3.0L Diesel Engine and 2020-2022 Model Year Super Duty with 6.7L Diesel Engine Nitrogen Oxide (NOx) Sensor Replacement, If Required After Dealer Evaluation Reference: Emissions Recalls 22E02, 22E04, 23E01, and 25E09

25S75 Recall remedy -Powertrain Control Module update to introduce logic to prevent low pressure fuel pump binding and maintain fuel flow to the engine.

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

25S75 Recall remedy -Powertrain Control Module update to introduce logic to prevent low pressure fuel pump binding and maintain fuel flow to the engine.

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.