The National Highway Traffic Safety Administration (NHTSA) launched a detailed investigation in June 2022 into the Ford Bronco following three petitions filed earlier that year. The investigation initially focused on alleged valve defects in selected Bronco models. However, the NHTSA has now expanded its inquiry to include over 700,000 Ford and Lincoln vehicles.

The initial investigation looked into over 25,000 2021 Broncos equipped with the 2.7-liter EcoBoost engine. This was prompted by 26 complaints regarding a potential loss of power at highway speeds without the ability to restart. The NHTSA attributed this power loss to “catastrophic engine failures” resulting from the failure of engine valves.

Last week, the NHTSA’s Office of Defects Investigation elevated the investigation to the engineering analysis stage after Ford provided evidence including 328 customer complaints, 487 warranty claims, and 809 engine exchanges. These cases involved 2021-22 Ford Bronco, Edge, Explorer, and F-150 vehicles, as well as 2021-22 Lincoln Aviator and Nautilus models, all equipped with either the 2.7-liter or 3.0-liter EcoBoost engines. It is important to note that despite these concerns, there have been no reports of injuries, accidents, or fatalities associated with this issue.

In a document, the NHTSA stated, “During the investigation, multiple contributing factors were identified, which can lead to the fracturing of the intake valves in the subject engines. Ford acknowledged that a fractured intake valve can result in catastrophic engine failure and a loss of power, and noted that after a valve fracture, a vehicle typically requires a full engine replacement.” A Ford spokesperson told Automotive News that the company is working with the NHTSA to support the investigation.