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 Lights stopped working. Unable to fix unless the whole light assembly is replaced.

NHTSA ID

11766824

Incident

May 1, 2026

Daytime Running Light in the headlight assembly overheated and stopped working. Thousands of 2021-2023 F150 owners have had the same issue. This is clearly a mass scale manufacturer known defect and Ford already tried sending an update to lower the LED brightness but the issue still happens.

NHTSA ID

11765572

Incident

Aug 25, 2026

ON YOUR VEHICLE, THE WHEEL END HUB BOLT IN THE REAR AXLE MAY BECOME LOOSE OR BREAK. CONTINUED DRIVING WITH A BROKEN BOLT MAY LEAD TO WEAR WITHIN THE AXLE AND DAMAGE THE AXLE HUB SPLINES. I’ve been contacting ford dealerships in my area trying to get this safety recall replaced over the last year every two or three months. I get the same excuse the part is on back order, we have 70,000 on back order others have said 35,000. Yet there is no timetable for when the part will be available. In the meantime I have to drive a vehicle that has had the top of the bolt connecting the tire to the axel snapped off. Ford has completely failed in remedying this issue since the recall and by their numbers making it so 70,000 people possibly have a broken vehicle that they are not repairing or replacing like the safety recall states.

NHTSA ID

11765354

Incident

Dec 31, 1969

Fuel pump failed while driving causing vehicle to be disabled in a roadway blocking traffic. The vehicle was then incapable of shifting to neutral so that it could be moved out of the roadway. A Ford dealer confirmed the faulty fuel pump and replaced the part. Ford appears to know this is a safety issue as per recall campaign 25S75/25V455 but they have refused to pay for the replacement fuel pump.

NHTSA ID

11764898

Incident

Aug 30, 2026

The contact's son owns a 2021 Ford F-150. The contact stated that her son reported that while accelerating from a complete stop, the vehicle hesitated significantly and shifted hard while the accelerator pedal was depressed. The vehicle was towed to the dealer, where it was diagnosed with transmission failure. The dealer determined that the transmission needed to be replaced, and the vehicle was repaired. The contact received notification of NHTSA Campaign Number: 26V402000 (Power Train), which the contact associated with the failure. The manufacturer was notified of the failure and informed the contact that reimbursement could only be provided when the recall remedy became available in April 2027. The failure mileage was approximately 113,468.

NHTSA ID

11764618

Incident

Feb 16, 2026

Mileage

113,468 mi

The contact owns a 2021 Ford F-150. The contact stated that while attempting to shift into park (P), the gear shifter became stuck, requiring the contact to remove the key from the ignition or depress the brake pedal until a whining sound ceased in order to shift into park (P). The contact stated that while operating the vehicle in reverse (R), the vehicle suddenly shifted into park (P) and stopped immediately. The failure recurred several times while in reverse (R). The vehicle was taken to the dealer, where it was confirmed that the VIN was not included in a recall. The failure mileage was approximately 53,000.

NHTSA ID

11764607

Incident

Sep 16, 2024

Mileage

53,000 mi

My husband was driving on the highway with my two daughters in the car when the vehicle stopped driving and he was barely able to pull off the road. It appears to be a defective low-pressure fuel pump. This is an active recall for this model and year, however Ford says that our specific VIN was not involved in the recall. My family could have been killed in this incident!

NHTSA ID

11764236

Incident

Sep 14, 2026

Led headlight drl strip turned blue on one side. Have seen many with this issue in the led module ballast. Safety concern because its a common running light issue that hinders people from seeing the vehicle as easily.

NHTSA ID

11764019

Incident

Sep 12, 2026

This bulletin updates 26-2206. Reason for update: update the Service Procedure to revise Steps 19-21, adding Step 22, and adding Figure 15-16 to clarify connector C316 location. Some of the vehicles listed in the Model statement above may exhibit diagnostic trouble codes (DTCs) C1001:31, U3000:89, and/or U3000:49 stored in the image processing module A (IPMA) and at least one of the following conditions:  "Front Camera Fault Service Required" message  Pre-collision assist inoperative  Adaptive cruise control inoperative  Front windshield camera alignment routine fails to complete This may be due to the coaxial cable between the IPMA camera and the IPMA.

This article supersedes 26-2287. Reason for update: update the labor operation numbers to add MT to operations C, F, G, H, J, K, L and M, and correct the part number LIMZ-4A015-B to L1MZ-4A015-B. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions:  Harsh engagement  Delayed engagement  Harsh shift  Delayed shift  Illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC)s P0751, P0752, P0756, P0757, P0761, P0762, P0766, P0767, P0771, P0772, P2700, P2701, P2702, P2703, P2704, P2705, P2707, P2708, P0729, P0731, P0732, P0733, P0734, P0735, P0736, P076F, P07D9, P07F6 and/or P07F7 stored in the powertrain control module (PCM) or transmission control module (TCM). This may be due to axial movement of the CDF clutch cylinder sleeve causing hydraulic circuit leaks. NOTE: If internal transmission service is required to address a concern detected with the CDF clutch cylinder following this article, technicians should carefully inspect and replace other transmission components and flush transmission fluid cooler only as ne

For Various Ford and Lincoln vehicles, if diagnostics lead to the replacement of the front seat cushion cover J-clips, lower-level service parts are now available. Use service part W709919-S901 if the J-clip is completely detached from the seat cover and W715386-S424 if the clip is still partially attached. It is not necessary to replace the seat cover if only the J-clip is separating from the cover. Refer to PTS Home > Technical Assistance > Technical Support Videos > Section 501- Body and Paint > Seat J-Clips. For claiming, use causal parts from list below and labor operations 63100A and 63100A5. Causal Parts for claiming: Bronco/Bronco Sport/Escape/Explorer/Expedition/Navigator: 7862900 or 7862901 F-150/F-Super Duty: 1562900 or 1562901 Ranger/Maverick: 6062900 or 6062901

Some 2021-2026 F-150 vehicles may exhibit a concern of the windshield wipers not parking in the correct position on the windshield and/or over-traveling. This may be due to incorrect alignment of the wiper pivot arm on the wiper linkage assembly. Wiper pivot arms may or may not be equipped with an alignment key. Alignment keys are a manufacturing aid and are not needed for proper alignment and operation. In some instances, it may be necessary to remove this alignment key to achieve proper alignment. Replacement of the wiper pivot arm, due to a missing alignment key is a not warrantable. Refer to Workshop Manual (WSM), Section 501-16.

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