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.

Drivers side seat controls (drivers side door), light which illuminates controls, started flickering incontrollably at +/- 33,000 miles, causing significant distraction to the driver as is within drivers' peripheral vision, during nightime driving. Reported to dealership McDavid Lincoln Frisco, states there is a failure in the seat control unit, causing the light flicker, and recommended a replacement of the whole seat control unit. 10/23/26, Repair has not yet been authorised, as vehicle is just out of the 4 year warranty period.

NHTSA ID

11773694

Incident

Sep 9, 2026

The contact owns a 2022 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 the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The manufacturer was made aware of the issue and confirmed that parts were not yet available.

NHTSA ID

11772963

Incident

Jul 7, 2025

The contact owns a 2022 Lincoln Aviator. The contact stated that upon parking the vehicle after an extended road trip, the contact noticed that the driver’s side and passenger’s side rear doors window bars and C-pillar trims had detached. The contact associated the failure with NHTSA Campaign Number: 25V407000 (Structure). The vehicle was taken to the dealer, where the failure was confirmed but the contact was informed that the vehicle was not covered because the VIN was not included in the recall. The failure mileage was approximately 82,000.

NHTSA ID

11772733

Incident

Oct 18, 2026

Mileage

82,000 mi

My vehicle’s alarm repeatedly activates while the vehicle is parked, turned off, and locked, approximately every 15 minutes. When the vehicle is unlocked, the front and rear lights remain illuminated even though the vehicle is turned off and the keys are not in or near it. The battery was tested twice after the vehicle had been at rest before I brought it to the dealership. The dealership subsequently replaced the battery for approximately $350, stating that this would likely resolve the symptoms. The dealership then performed a $250 diagnostic and advised that the rear passenger door latch had failed and the overhead front light console was shorted and needed replacement. I am concerned about the unexplained lighting and electrical malfunctions, repeated alarm activation, and resulting battery depletion and starting reliability. I have also experienced intermittent difficulty starting the vehicle, unusually shrill startup warning sounds, and failure of the normal startup display to appear. I do not know whether these symptoms share the same underlying cause. I have seen numerous reports from other Lincoln owners on Reddit describing rear passenger door latch failures causing repeated alarm activation. I request that NHTSA assess whether these reports and my experience indicate a recurring safety-related defect warranting investigation. The dealership’s diagnosis concerns the door latch; I have not observed the door opening unexpectedly.

NHTSA ID

11772184

Incident

Oct 1, 2026

The contact owns a 2022 Lincoln Aviator. The contact stated that while driving at various speeds, the vehicle experienced excessive fuel consumption and reduced power, hesitation and jerking while accelerating. Additionally, while turning left, the steering was difficult to turn. The contact stated that there was an abnormal burning odor while driving at high speeds. The contact associated the failure with the wheels, and the vehicle was taken to the Chevrolet dealer where it was purchased and an alignment was performed; however, the failure persisted. The contact was advised that the failure might be associated with NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, a local dealer and Webb Ford, Inc. (9809 Indianapolis Blvd, Highland, IN 46322); informed the contact that parts were not yet available for the recall repair. The manufacturer, Ford Motor Company, was contacted and confirmed that the part was unavailable. The failure mileage was approximately 34,000.

NHTSA ID

11764106

Incident

Aug 10, 2026

Mileage

34,000 mi

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

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

This bulletin supersedes 26-2309. Reason for update: update the Model section to remove Aviator 10R80, update theParts list to add 3.3L to W520514-S440, and add L1MZ-7Z490-G valve body separator plate for Aviator

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.