2022 Lincoln Nautilus

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 door hinge has completely broken away from interior side panel. This is a know manufacturing defect due to the weight of the door on this vehicle. We called dealership on 5/4/2026 after discovering issue, spoke with the service manager who advised us to bring vehicle to the dealership. On 5/5/2026 the vehicle was brought to Tasca Collision Center a service team member took extensive pictures of damage, stated how the repair would go forth which has since not happened. Tasca and Lincoln have refused to make repair stating that the vehicle was out of warranty effective 5/4/2026. This is also a safety issue in the advent of a side crash.

NHTSA ID

11754440

Incident

May 4, 2026

Spot welds in both front doors are failing. How would these cars do in a side impact with failing spot welds? The drivers door has approximately a 4" tear/crack around the broken spot welds.

NHTSA ID

11751759

Incident

Apr 1, 2026

Lincoln Nautilus door hinge and check strap area of the driver's door has a significant crack which could lead to door failure in the event of a crash. Manufacture has issued a CSP (Customer Satisfaction Program 23B56. Year models 2022-2024. Mine is a 2022 but the VIN does not fall in the range of known defects. Mfg. refused repair based on the VIN, but all other criteria have been met. Dealer acknowledges the defect.

NHTSA ID

11746052

Incident

Jun 17, 2026

The sheet metal around both front door hinges are cracking. Just as the Ford Escape did.

NHTSA ID

11735966

Incident

Apr 17, 2026

Good afternoon, I am an owner of a 2002 Lincoln Nautilus. I wanted to report an electrical/battery issue with the vehicle that started a year and a half ago. In the past year and a half I have had 2 battery replacements with the most recent one being changed end of December of 2025 and in early March the battery went again so it's not even 3 months that it lasted. The battery completely dies and each time I have to jump start it in order to have a vehicle to work or take my kids places. As a single mom I do not want to put my safety or my kids safety at risk if I get stranded somewhere at night time with no means of getting it jump started. Upon reading some reviews online, I have noticed a lot of Lincoln owners especially the years of 2022-2023 have complained and reported the same issues with dealerships just changing out their batteries and not looking for the deep problem. I have dropped off the car at the dealership and they do not what's causing the issue. My car warranty has 300 miles left and they told me after my bumper to bumper expires there is not much they can do to cover it. I was wondering if this was ever reported or has there been previous recalls on it. Thank you very much for your time.

NHTSA ID

11725508

Incident

Mar 1, 2026

The transmission jerks at low speeds between 10mph-60mph. Has been duplicated at Lincoln dealership. A torque converter was replaced , but did not correct problem. I know that there is a class action suit for this problem for 2019-2021 it needs to add the 2022 suv also. Lincoln paid for parts , I paid labor . Total repair was 2200$

NHTSA ID

11722407

Incident

Jan 5, 2026

The contact owns a 2022 Lincoln Nautilus. The contact stated that while another person was driving approximately 15-50 MPH, the vehicle sputtered and jerked. The vehicle was driven to the workplace, and the contact attempted to test-drive the vehicle. The contact stated that upon starting the vehicle and shifting to drive, there was delay while responding, with a clunking sound coming from the vehicle. The contact stated that the vehicle failed to shift into gear the following day. The contact stated that upon shifting to reverse, the vehicle jerked forward, and upon shifting to park(P), there was a delay before the vehicle responded. There was a delay after shifting out of park(P). There was no warning light illuminated. The vehicle was towed to the dealer, where several internal diagnostic trouble codes were found. The dealer determined that the transmission had failed and needed to be replaced. The contact related the failure to NHTSA Campaign Number: 22V413000 (Power Train). The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided because the VIN was not included in the recall. The failure mileage was approximately 149,200.

NHTSA ID

11715875

Incident

Feb 5, 2026

Mileage

149,200 mi

There is a class action lawsuit for the 2019-2021 Nautilus with the 8F35 transmission, which is the same transmission that my 2022 Nautilus has. Ford has also issued multiple technical service bulletins (25-2154, 21-2389) regarding the 8F35 transmission. My transmission has had a catastrophic failure and began slipping out of gear while driving on the highway. The vehicle lost power several times while driving. The wrench light came on. I was able to make it to the dealership where they are quoting me for a total replacement of the transmission. One week prior, I brought the vehicle in to reprogram the PCM due to a recall alert I got from the Lincoln app. I was experiencing jerking and shuddering prior to the PCM reprogram, then within days of the reprogramming, the transmission completely failed.

NHTSA ID

11708334

Incident

Dec 26, 2025

Some 2021-2026 Ford/Lincoln vehicles may exhibit various symptoms including but not limited to the auto start/stop system not operating as intended with a "Check Charging System" message in the instrument panel cluster (IPC) while the charging system is operating properly with no charging related diagnostic trouble codes (DTC) stored. This may be due to someone using an aftermarket programmer to change the body control module (BCM) configuration to disable the auto start/stop system or perform other unsupported programming modifications. To correct this condition on F-150 and Bronco vehicles, download and run the Ford Diagnosis and Repair System (FDRS) application titled "BCM-Charging System Configuration Correction". Running this application will determine if the BCM configuration was modified by the customer and if so, provide the option to return the configuration back to factory settings. For other vehicle models exhibiting concerns related to unsupported aftermarket BCM programming, submit a Technical Support Request (TSR) requesting support to revert the BCM configuration

This bulletin supersedes 26-2171. Reasons for update: update the Parts list to add a note to clarify the application of the part numbers W520102-S442 and 4S4Z-3N324-AA "FWD Only". Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder condition, most noticeable at speeds below 60 mph (100 km/h)  No relevant diagnostic trouble codes (DTC) present  Traceable shudder event with IDS/FDRS reading *(Figure 1)* This condition may be perceived/felt as an engine misfire. This may be due to a concern with the output planetary assembly.

This bulletin supersedes 26-2194. Reason for update: update the Parts list to correct a part description " Loctite 638", update the claim quantity for the drain/fill plug, update the claim quantity of the wheel hub bolts (Corsair) and limited the parts list for Edge/Nautilus to only the rear drive unit fluid. Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder chatter condition, most noticeable at low speeds turning  No relevant diagnostic trouble codes (DTCs) present This may be due to internal rear drive unit (RDU) fluid contamination.

Quality improvements include: - Enhanced system performance, disk usage limits and memory monitoring

Some of the vehicles listed in the model statement above equipped with SYNC4 may experience a blank center display screen or black center display after welcome animation. The rear-view camera will still function when shifting the vehicle to reverse under these conditions.

This bulletin supersedes 25-2627. Reason for update: To add a Step to reprogram the all-wheel drive (AWD) module for Bronco Sport vehicles. Some of the vehicles listed in the Model statement above may exhibit all of the following conditions:  Shudder chatter condition, most noticeable at low speeds turning  No relevant diagnostic trouble codes (DTCs) present This may be due to internal rear drive unit (RDU) fluid contamination.