2021 Lincoln Aviator

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.

The driver's side door latch assembly (Part Number LC5Z-54219A65-H) on my 2021 Lincoln Aviator with approximately 79,300 miles has begun intermittently failing to latch when the door is closed. This issue first started approximately three weeks ago. The driver's door often requires multiple attempts to close before the latch finally engages. When it does latch properly, a distinct loud click can be heard. Prior to that click, the door may appear closed but is not securely latched. This is a major safety concern because there is no reliable way to know whether the driver's door will remain closed while the vehicle is being operated. I am concerned that the door could unexpectedly open while driving, creating a serious risk of injury to the driver, passengers, and other motorists. I contacted my Lincoln dealership and was informed that the replacement door latch was on backorder. The dealership advised that there were approximately 80 other requests for the same part. This raises concerns that the issue may be more widespread than an isolated failure. The vehicle is scheduled for repair on November 6, 2026. I have been advised the repair will require the vehicle to remain at the dealership for more than one day. The vehicle was previously involved in a front-end collision; however, the damage was limited to the front bumper and related electronic components. There was no damage to the driver's door, door frame, latch assembly, or surrounding door structure. The current door latch failure developed long after the front-end repairs and appears unrelated to that accident. Because the driver's door latch is a critical safety component, I believe this condition warrants investigation. A door that does not consistently latch and remain secured during vehicle operation presents a significant safety hazard.

NHTSA ID

11775885

Incident

Oct 12, 2026

The contact owns a 2021 Lincoln Aviator. The contact stated that while the vehicle was parked in the driveway, the panoramic sunroof gasket deteriorated with chunks of the gasket missing. The contact inspect the gasket and became aware that the part was damaged by the elements. The contact was concerned that the gasket would allow water to leak into the vehicle. A dealer inspection appointment was scheduled. The failure mileage was approximately 98,000.

NHTSA ID

11774161

Incident

Oct 27, 2026

Mileage

98,000 mi

I have a Lincoln Aviator 2021 that has had at least 6 recalls. I love Lincoln’s but this is ridiculous. I have 3 open right now with no remedy available. The first notice came to me March 2026. I haul grandkids a lot, my vehicle needs the recalls fixed so my vehicle is safe. Can anything be done about this?

NHTSA ID

11768999

Incident

Mar 1, 2026

The Driver Seat Module (DSM) is known to develop software glitches across the 2020–2024 Aviator/Corsair/Explorer platform, causing the seat to not move to the correct programmed memory position . Lincoln’s fix (per Special Service Message 51406, issued for Corsair but describing the same shared module) is a dealer reprogram of the DSM software. However, this did nothing to improve the problem. •Symptoms include complete loss of seat adjustment where switches do nothing and the seat is stuck in place, memory functions failing to recall saved positions, intermittent operation with clicking noises but no movement, and the easy entry/exit function drifting out of correct position over time. Additionally, the drivers seat bladders and actuators engage without driver input and the seat controls on the touchscreen, increase and decrease bladder input and motor control beyond the selected settings. This often HAPPENS WHILE DRIVING.

NHTSA ID

11764001

Incident

Sep 14, 2026

I have been having issues with my breaks sticking when applied. To the point that it’s completely stopping my car and i need to use my foot to release the brake from behind. I have had the dealership look at this issue and they can’t seem to find the problem. They also broke my car and claimed they did not feel the sticking. I’ve had the dealership look at my vehicle twice for this issue. It is a safety risk with children in my vehicle. Also everyone i lock my vehicle. My alarm is going off saying someone is opening the door on my Lincoln app. Additionally, every time i start my car it says the passenger door is open, when it’s not. The sync Bluetooth constantly connects and disconnects or if i plug my phone i to the charger for CarPlay it does not work. This biggest problem is my brakes sticking. Like i said when i am braking gradually they are sticking to the floor and not releasing. Thai doesn’t always happen but it has happen a lot recently. I need this fixed!!!!! Multiple recalls that are not available as well

NHTSA ID

11751230

Incident

Jul 7, 2026

The contact owns a 2021 Lincoln Aviator. 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 70-75 MPH, the check engine warning light illuminated, and the vehicle stalled. The vehicle was towed to a friend's residence, where it failed to restart. The dealer was contacted and informed that the vehicle would be repaired at the owner's expense because the recall remedy was unavailable. The contact was informed that a reimbursement claim could be filed with the manufacturer afterwards. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not notified of the failure. The failure mileage was approximately 67,000.

NHTSA ID

11750650

Incident

Jul 12, 2026

Mileage

67,000 mi

The contact owns a 2021 Lincoln Aviator. The contact received notification of NHTSA Campaign Number: 26V117000 (Visibility); however, the part to do the recall repair was unavailable. The dealer was contacted, and the contact was informed that parts would be available at the end of June 2026. The manufacturer was not contacted. The contact had not experienced a failure.

NHTSA ID

11750524

Incident

Jul 15, 2026

The contact owns a 2021 Lincoln Aviator. The contact stated that while the vehicle was unoccupied and parked on an incline, the vehicle rolled backwards several feet and then came to a complete stop. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact related the failure to NHTSA Campaign Number: 26V402000 (Power Train); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was approximately 98,000.

NHTSA ID

11747408

Incident

Mar 15, 2026

Mileage

98,000 mi

Special Field Action 26L03 Certain 2013-2024 Model Year California Emissions-Certified Vehicles Transmission Fluid Auxiliary Pump Reimbursement

Some 2020-2026 Aviator/Explorer/F-150/Bronco/Ranger vehicles equipped with a 2.7L or 3.0L (non-diesel) engine may need the front engine cover removed and reinstalled for various reasons. The Workshop Manual (WSM), Section 303-01 Engine > Removal and Installation > Engine Front Cover service procedure has been updated to include a new essential special service tool (ESST) guide pin alignment tool (303-1790) that is used to align the engine front cover to the engine block, preventing the O-ring seal on the engine oil galley feed tube from getting damaged during installation.

For 2020-2026 Aviator/Corsair and 2018-2026 Navigator vehicles, if diagnostics in Workshop Manual (WSM) Section 501-10A > Front Seats > Diagnosis and Testing lead to the replacement of the front seat cushion extension adjuster, a lower-level part is now available (14C720). It is not necessary to replace the front seat cushion extension adjuster if only the front seat cushion extension motor assembly is damaged. For Corsair, use service part LJ7Z-14C720-A. For Aviator, use service part R2TZ-14C720-A. For 2025-2026 Navigator (both sides) and 2018-2024 Navigator driver side, use service part NL7Z-14C720-A. For 2018-2024 Navigator passenger side, use service part NL7Z-14C720-B.

Some 2020-2024 Explorer/Aviator vehicles equipped with 3.0L EcoBoost/hybrid engine may exhibit blue or black exhaust smoke on startup for the first 5 minutes after an overnight cold soak with no illuminated malfunction indicator lamp (MIL) or powertrain diagnostic trouble codes (DTCs) present. This may be due to engine oil breaching the dynamic oil seals separating the bearing core from the turbine housing in the left side turbocharger assembly. There is a new, updated left side turbocharger oil supply tube equipped with an internal check valve to prevent the engine oil from entering turbine housing after the engine is off. Replace the existing left side turbocharger oil supply tube with the updated service part that includes the check valve (service part# L1MZ-9T516-B) or latest level part. Refer to the Workshop Manual (WSM), Section 303-04 Fuel Charging and Controls - Turbocharger > Removal and Installation > Turbocharger Oil Supply Tube LH. For claiming, use causal part 9T516 and labor operation code 9440AL.

Some of the vehicles listed in the Model statement above may exhibit a front courtesy lamp that is inoperative. This may be due to a concern with the front courtesy lamp light module.

This article supersedes TSB 25-2373 to update a print error on publication. Some vehicles listed in the model statement above may exhibit an illuminated powertrain malfunction (wrench) indicator with diagnostic trouble codes (DTCs) C00A6 and/or C0631. This may be due to the front axle disconnect actuator/intermediate shaft.