According to Carscoops, Ford is preparing for a new recall in the US, affecting over 90,000 of its popular pickup trucks and SUVs.

The issue at hand is quite serious. Ford has identified that the intake valves on their 2.7L and 3.0L EcoBoost V6 engines are prone to cracking and breaking. This could potentially lead to what Ford describes as “severe engine damage,” resulting in reduced performance and an increased risk of accidents.

The recall notice sent by Ford to the National Highway Traffic Safety Administration (NHTSA) states that the engine intake valves may fail at the third retainer groove within the valve.

This recall has been in the works for quite some time, with Ford initiating an investigation into the 2.7L and 3.0L EcoBoost engines back in January 2022, after recording a total of 22 failures.

The issue became so severe that the NHTSA’s defect investigation office had to launch a probe in October 2023, encompassing no fewer than 708,837 vehicles.

The 2.7L EcoBoost V6 engine in Ford vehicles has the potential to break during operation. Image: Ford.

The affected models include 15,835 Ford Broncos produced between May 1, 2021, and October 30, 2021, as well as 47,719 Ford F-150 pickup trucks manufactured between May 1, 2021, and October 31, 2021.

The recall also includes the 2021-2022 Ford Edge, 2021-2022 Lincoln Nautilus, and 2021-2022 Lincoln Aviator. Additionally, the 2021-2022 Ford Explorer, produced between June 7, 2021, and October 31, 2021, will also be part of this recall.

Owners of the affected vehicles will receive notification about the recall starting October 7. In the event that any vehicle fails a high-cycle engine test, the engine will be replaced.

Last year, Ford issued 54 recall orders, affecting nearly 5.7 million vehicles in the US. However, in just the first half of this year, Ford and Lincoln have already conducted 31 recalls, impacting close to 3.7 million cars, trucks, and SUVs.

As it stands, Ford is currently the automaker with the most recalls in the US in 2024, both in terms of the number of vehicles affected and the number of recall orders issued. This continues a trend from the previous years, as Ford repeatedly topped the list of automakers with the most recalls between 2021 and 2023.

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