2022 Ford F-150

On July 29, 2024, the Office of Defects Investigation (ODI) opened PE24019 to investigate complaints of low-pressure fuel pump failures in MY 2021 Ford Bronco vehicles. Some consumers reported that the failure occurred without warning while driving, resulting in a complete loss of motive power with no ability to restart the engine. Ford determined that several other vehicle models contain low-pressure fuel pumps substantially similar to the 2021 Ford Bronco, including the 2022-2023 Ford Bronco, 2018-2023 Ford F-150, 2022-2023 Ford Expedition, 2019-2023 Lincoln Navigator, 2020-2023 Ford F-250-F-550, 2024 Ford Super Duty Chassis Cab, 2024-2025 Ford Ranger, 2020-2023 Ford Explorer, 2020-2023 Lincoln Aviator, and 2021-2025 Ford Mustang. ODI's investigation found that the affected vehicles may lose fuel pressure and flow from the fuel delivery module (consisting of a low-pressure fuel pump, jet pump, reservoir, and other parts) due to a low-pressure pump failure. This can cause the engine to stall while driving. The root cause is reduced internal clearance in the fuel pump, increasing friction and sensitivity to vapor lock. Fuel blockage from contamination inside the jet pump also contributed to the failure. Ford stated that the contamination source was unknown. On July 7, 2025, Ford filed recall 25V-455 for certain 2021-2023 Ford F-550 SD/F-450 SD/F-350 SD/F-250 SD, 2021-2022 Lincoln Navigator, 2021-2022 Ford Mustang, 2021-2022 Ford F-150, 2021-2023 Ford Explorer, 2022 Ford Expedition, and 2021-2023 Ford Bronco vehicles produced between July 1, 2021, and July 30, 2022. The recall also included certain 2021-2023 Lincoln Aviator produced between July 1, 2021, and December 21, 2022. Ford explained in its recall filingthat the production dates used for the recall were based on changes in the manufacturing process. Specifically, Ford determined that in June 2021, the supplier modified the jet pump manufacturing process, producing fuel pump chambers with a lower-than-specified internal clearance. In July 2022, the supplier implemented corrective actions to the manufacturing process by adding two additional vacuum pumps to reduce contamination during the production of the jet pump. ODI has identified approximately 1,000 reports involving vehicles covered in this investigation but excluded from recall 25V-455. However, even with such reports, these vehicles experienced comparatively lower failure rates than the vehicles that are subject to Recall 25V-455. Ford has explained that these vehicles were excluded from the recall population because they did not experience the manufacturing changes that prompted the recall. Specifically, according to Ford, vehicles built before July 1, 2021 (the recall production start date), were not affected by the supplier’s change to the jet pump manufacturing process. Even after closing this investigation, ODI will continue to monitor complaints for vehicles excluded from recall 25V-455 to consider whether they exhibit the same risks as the vehicles encompassed by the recall. The recall remedy is currently under development. In view of Ford’s recall action, ODI is closing this Preliminary Evaluation, but will continue to monitor the issue as a remedy is developed and implemented. ODI will take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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.

I am reporting a safety-related transmission problem I experienced with my 2022 Ford F-150 equipped with the 10R80 automatic transmission. While driving normally, the transmission suddenly downshifted and slipped gears and jumping up gears. This occurred while taking off and slowing down creating a potentially dangerous situation because the truck did not respond as expected when I needed predictable acceleration or propulsion. I believe this incident may be related to the known 10R80 CDF clutch-cylinder/sleeve problem. Ford technical information identifies axial movement of the CDF sleeve that can cause hydraulic-circuit leaks and harsh or delayed engagement and shifting. This condition can result in slipping, RPM flares, delayed engagement, unexpected gear changes, harsh downshifts, lurching, or loss of propulsion. This is a safety concern, not merely a transmission quality or reliability issue. Unexpected loss of propulsion or unpredictable shifting while merging, accelerating into traffic, crossing an intersection, turning, or traveling at highway speed can create a collision hazard. Because I personally experienced this unexpected transmission event, I request that NHTSA investigate the 10R80 CDF clutch-cylinder/sleeve condition in Ford F-150s. Please review Ford warranty claims, dealer repair records, transmission replacements, consumer complaints, and field-failure data to determine whether this is a safety defect requiring a recall. I believe owners should not have to wait for a potentially dangerous transmission failure before this known condition is addressed. I had my truck into a dealer in 2025 ( under warranty 44K miles )and they had admitted they were short handed for transmissions and after eight days I called them and they said just come pick it up as they did not find any issues. Fast forward to this year 68K miles and they said it needed to be completely replaced with a new one for $14,000.

NHTSA ID

11766300

Incident

Jun 25, 2026

The passenger side daytime running light has now failed leaving the vehicle less visible during low visibility times like fog or dawn and dusk. Problem can be reproduced but has not been inspected yet. No warning lamps or symptoms prior to failure. Problem occured 9-19-2026

NHTSA ID

11765728

Incident

Sep 19, 2026

Daytime lights failed while driving

NHTSA ID

11765579

Incident

Sep 19, 2026

My F 150 is 2022 Xlt my headlights are going bad already I’ve taken it to the dealership and said both complete headlight assembly need replaced to the tone of 4.000 dollars

NHTSA ID

11765240

Incident

Jun 13, 2026

JUL 08, 2025 Manufacturer Recall Number25S75 NHTSA Recall Number25V455 Recall StatusRecall Incomplete, remedy not yet available This recall has been pending since 07/2025.why is there still no remedy?why is Ford not addressing this recall?

NHTSA ID

11764884

Incident

Jul 24, 2025

The contact owns a 2022 Ford F-150. The contact stated that while the vehicle was parked in the garage, the parking brake activated independently. The failure was a recurring failure. The contact associated the failure with NHTSA Campaign Number: 23V509000 (Parking Brake); however, the VIN was not included in the recall. The dealer was contacted and stated that the repair was not covered because the VIN was not included in the recall. The manufacturer was contacted by phone and was made aware of the failure. The failure mileage was approximately 40,000.

NHTSA ID

11763028

Incident

Jul 7, 2026

Mileage

40,000 mi

The daytime running lights are out. Vehicle is available for inspection. This puts my safety and the safety of others at risk by not being o by reducing visibility of the vehicle during low light scenarios where the headlights are off. Example I live in an area with lots of fog and drive a gray vehicle that is not clearly visible if headlights are off due to light exposure. Problem is consistent and able to be reproduced for inspection. Vehicle has not been inspected by any agent to this point but it is available and will be noticed upon inspection by direction. There are no warning lamps or messages alerting driver of malfunction which poses another safety risk. Problem has been consistent for past 3 weeks upon every start.

NHTSA ID

11762636

Incident

Aug 16, 2026

The contact owns a 2022 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 contact stated that while driving at various speeds on several occasions, the vehicle experienced a temporary loss of motive power while accelerating and turning. The contact stated that the failure was a recurring failure, and the contact needed to maintain a fuel level above half tank. The vehicle was taken to a dealer, where it passed the State Inspection, and the contact was advised to wait until the recall part was available for the repair. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. Additionally, the contact became aware that the VIN was included in NHTSA Campaign Number: 26V104000 (Electrical System, Exterior Lighting); however, the contact had not received the recall notification. The failure mileage was approximately 20,000.

NHTSA ID

11762226

Incident

Jan 4, 2025

Mileage

20,000 mi

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 2022-2026 F-150 Lightning vehicles may exhibit a reduced distance to empty (DTE) projection, a high voltage battery pack state of charge (SOC) that drops from 100% to less than 90% within 60 seconds of being driven, and an inability to reach a target SOC using the scheduled charging feature without any diagnostic trouble codes (DTCs) in the battery energy control module (BECM). This may be due to an issue in one or more cells within the high voltage battery pack. To correct the condition, run the "BECM Battery Health" application using the latest software version of the Ford Diagnosis and Repair System (FDRS). If any cells are identified as exceeding state of charge and/or capacity thresholds, refer to the Workshop Manual (WSM), Section 414-03A High Voltage Battery, Mounting and Cables > Diagnosis and Testing > High Voltage Battery, Mounting and Cables  Electric. Perform Pinpoint Test High Voltage Battery Pack Cell Balancing Faults, Step 4 (PPT Step AO4 for 2022-2024 vehicles/PPT Step AQ4 for 2024-2026 vehicles) and proceed with Pinpoint Test directions following the results of Step 4.

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.