2022 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 contact owns a 2022 Lincoln Aviator. The contact stated that while driving at various speeds, the second-row rear seats folded independently while the contact’s daughter was seated in the second-row seats. The failure caused bruises on the child's face and arms on several occasions. Medical attention was not sought. The contact stated that while the child safety seat was strapped into the second-row seats, the seat independently unlatched and became unsecured. The vehicle was taken to a local dealer where it was diagnosed; however, no cause for the failure was found. The vehicle was taken to another local dealer, Hagerstown Ford (1714 Massey Blvd, Hagerstown, MD 21740) for a second opinion, where it was diagnosed, and both second-row seats failed a safety inspection. The vehicle was not repaired. Upon further investigation, the contact associated the failure with NHTSA Campaign Number: 26V451000 (Seats); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was approximately 54,000.

NHTSA ID

11754896

Incident

May 15, 2026

Mileage

54,000 mi

While driving, there is a loss of fuel pressure at random. It has happened when stopped at traffic light and while driving on the freeway, the vehicle does not respond to the gas pedal being pressed. This is unsafe for myself and my passengers, as I cannot confidently change lanes as I never know when it will happen. The problem has been reported to the dealership, but no confirmation on their ability to reproduce this. It was announced as a recall issue 07/2025 but still not resolution. There are never any warning lights before this happens, so its always a surprise when it happens.

NHTSA ID

11740055

Incident

Jul 5, 2025

The contact owns a 2022 Lincoln Aviator. The contact received notification of NHTSA Campaign Numbers: 26V123000 (Back Over Prevention) and 25V455000 (Fuel System, Gasoline); however, the parts for the repairs were unavailable. The contact stated the manufacturer had exceeded a reasonable amount of time for the remedy to be available. The contact stated that the back over camera and alarm system would fail intermittently, and the park aid stopped message would display on the vehicle. The dealer was contacted, and it was confirmed that the remedy for 26V123000 (Back Over Prevention) would not be available till Q2 OF 2026, and they were unsure of when the remedy for 25V455000 (Fuel System, Gasoline) would be available. The manufacturer was not made aware of the issue. The contact had not experienced any failure was approximately 57,000.

NHTSA ID

11738033

Incident

Mar 5, 2026

Mileage

57,000 mi

Lincoln Way App team bricked (some) users by deploying an App update early Feb 2026 that was not backwards compatible for use of basic features/function. I last used App Jan 2026 while car was at dealer but when I picked up car 2/13/26 I was BRICKED with no ability to use App since. Checked Lincoln website & compatibility reqmt stated IOS 16.0 is min req’d, updates are optional & not required to continue use for basic features like lock/unlock, remote start, chk tire pressure, etc. (see screenshot attached). Opened case w/Lincoln Way App team 2/17/26. Ops mgr confirmed my iphone was compatible & iOS 16.0 was still min. reqmt. Said he’d escalate. Suddenly, wks later Lincoln updated website & changed compatibility requirements with NO NOTICE TO USERS (before or since) they’ve changed compatibility reqmts (they have users names, email, addr & phone #s since they’re req’d upon setup). In addition, NONE of the App version release notes shown in App Store indicate any change to Min compatibility reqmts. Development team is negligent & Lincoln needs to fix.

NHTSA ID

11730568

Incident

Feb 13, 2026

REF RECALL 26V117 (Wiper Motor failure) & MY (2) PRIOR NHTSA COMPLAINTS; 11681607 & 11688314 (Autosense wiper operation failure). Autosense wiping does not clear wIndshield enough for visibility & therefore can’t be relied upon for safe driving. The only way to get MANUAL INTERMITTENT wiper operation is to go to SYNC settings & turn off auto wiper while driving in rain on Hwy at 65+ mph. Seriously?! THIS IS DISTRACTED DRIVING AT ITS WORST. Took dealer 2+ yrs to discover the shipping protective film used on wiper sensor was NOT removed by Chicago assembly plant prior to installing the sensor. Apr 2025, dealer replaced my sensor however it failed again by Aug 2025. Dealer had car 10/28/25-12/22/25 to fix multiple issues incl Autosense wiping. No codes appear & they can’t ID root cause of problem. Took car back for service 12/29/25-2/13/26 (multiple issues incl this) & they still can’t ID root cause. Given there’s now also a recall for wiper motor failure I requested a loaner from Lincoln CHQ but they have refused. I’M REQUESTING NHTSA REQUIRE LINCOLN TO PROVIDE LOANERS UNTIL THEY FIX ALL WIPER OPERATION FAILURES.

NHTSA ID

11730564

Incident

Feb 13, 2026

REF C PILLAR RECALL & NHTSA Complaint # 11713372 by another owner on 11/18/25. NHTSA NEEDS TO ISSUE RECALL FOR A PILLARS. Have had wind noise issue on front passenger side since I bought car. Dealer looked at numerous times in 3 yrs & always stated ‘unable to recreate condition’ (likely due to not testing on Hwy at 65mph which is when this noise can be heard). Took car in for C Pillar recall fall 2025. Dealer said they weren’t loose so didn’t replace them. Left w/car 12/22/25 & immed heard wind noise on Hwy. Returned to service & this time, DEALER INSPECTED A PILLARS & FOUND RIGHT SIDE WAS LOOSE so replaced both. Tried to charge me (was 2 wks out of warranty) but given multiple attempted repairs during warranty & my open case w/CHQ they split repair cost. Thankfully A pillars didn’t break loose & injure human or another driver in past 3 yrs. Dealer told me Ford had A pillar recall but Lincoln’s weren’t included in it. There appears to be a pervasive issue with failure of the adhesive used for many parts by the assembly plant.

NHTSA ID

11730557

Incident

Feb 4, 2026

THIS REQUIRES A RECALL ASAP. Dealers are well aware of this problem as is Lincoln CHQ but Lincoln refuses to address it. Rear camera cannot differentiate between steady rain & an object which then causes car to engage the collision avoidance system which then prevents ability to drive in reverse gear. There have been many rearview camera recalls on this car & each has made things worse. The ONLY way I can drive car in reverse (in rain) is to TURN OFF collision avoidance system (insane). Having to turn off this safety feature when it’s needed the most (in rain) is VERY dangerous. I tapped a person backing out of a parking spot. He was walking in blind spot, couldn’t see him on rearview camera, parking sensor alerts failed, collision avoidance was off because I can’t drive in reverse in rain. Thank God he wasn’t injured. BEGGING NHTSA TO FORCE A RECALL BEFORE A HUMAN GETS RUN OVER.

NHTSA ID

11730549

Incident

Sep 15, 2025

Regarding safety recall notice 25S66/NHTSA recall 25V407 - we took our car to the local Lincoln dealer in Lubbock (Gene Messer Ford/Lincoln) in late November for the repair of the recall "C-Pillar Applique Delamination." There was considerable wind/rattle noise coming from the passenger side, which is a component of the recall. After completing the recall we noticed the wind/rattle noise is still there and even slightly worse. We have contacted the service representative at Gene Messer Ford/Lincoln regarding this and have yet to receive a reply. We are reaching out to you for a solution to the noise problem. Any help is much appreciated! Thanks for your time, [XXX] and [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11713372

Incident

Nov 18, 2025

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.

NEW VEHICLE DELIVERY HOLD - Emissions Recall 26E04 Certain 2021-2025 Model Year F-150, Maverick, Mustang, Ranger, Expedition, Bronco Sport, Explorer, Bronco, Navigator, and Aviator Vehicles Powertrain Control Module Software Update

This bulletin supersedes 26-2241. Reason For Update: update the parts list to correct the claim quantity of the part number JB3Z-4B496-B from 3 to 6. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: * Harsh 3-4, 4-5 upshifts * Harsh 5-3, 4-3 downshifts * Harsh reverse engagements These symptoms may be worse when cold. This may be due to the F clutch friction plates brinelling into the clutch and planetary container cylinder (7B177).

This article supersedes 25-2302. Reason for update: update the labor time allowance for F-150 vehicles, update the Parts list to replace the part number W716979-S439 with W721084-S439, and add a note for LV fluids XT-10-QLVC and CXT-10-LV6 "Transfer Case Fluid". 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 tra

For 20202026 vehicles equipped with the 10R60 transmission, a new Transmission Clutch Circuit Leak Test has been introduced in the Ford Diagnosis and Repair System (FDRS). This test utilizes the pressure and vacuum transducer (PVT) when available. Workshop Manual (WSM) updates related to this diagnostic procedure are planned for release in Q4 2026. The new test improves the accuracy of detecting leaks within transmission fluid circuits and replaces the previous air check method. The previous air check procedure has been shown to produce a high rate of false positives, which may lead to unnecessary repairs when no actual leak is present. Accordingly, the air check procedure is not to be used for diagnosing internal transmission hydraulic leaks or as justification for transmission replacement.

This bulletin supersedes 25-2587. Reason For Update: update the Parts list to add the F-clutch friction plates HL3Z-7B164-D and the F-clutch steel plates PR3Z-7B164-A for the proper vehicle lines, replace the transfer case mounting bolt part number from W714288-S438 to W714288-S437, update the part number W720688-S439 quantity from 2 to 1, update the part number ML3Z-7869-C claim quantity from 2 to 1 (only if necessary), update the description of CXT-10-LV6 and XT-10-QLVC by adding "transfer case fluid, 4WD only", move HL3Z-7A191-B and L1MZ-7F396-A fluid pan gaskets to the parts to inspect and replace list, and remove TL1Z-6775-A self adhesive heat shield from the F-150/Expedition/Navigator parts list as it is not a discard item. Some of the vehicles listed in the Model statement above may exhibit at least one of the following conditions: * Harsh 3-4, 4-5 upshifts * Harsh 5-3, 4-3 downshifts * Harsh reverse engagements These symptoms may be worse when cold. This may be due to the F clutch friction plates brinelling into the clutch and planetary container cylinder (7B177).