The Story Behind Ford’s EcoBoost Problems (And How They Are Being Resolved)

Ford’s EcoBoost engine family has earned the unfortunate nickname ‘EcoBoom’ due to its reputation for being plagued with issues. But what are the problems, and what is Ford doing to ensure they’re fixed? How can you check if your vehicle is affected? Read on to find the answers to these questions.

To be fair to Ford, there aren’t many automakers that haven’t experienced an NHTSA recall of one of their models. However, the issues seem to be never-ending for Ford, with the latest big recall involving models equipped with its 2.7-liter or 3.0-liter EcoBoost V-6, which affects tens of thousands of units, including many top models.

In order to give you the most up-to-date and accurate information possible, the data used to compile this article was sourced from Ford and other authoritative sources, including CarEdge, Hagerty, J.D. Power, the NHTSA, RepairPal, and USA Today.

Ford EcoBoost Engine Problems And Recalls

Right from the word go, Ford’s EcoBoost engine suffered a rough start. Introduced in 2009, the first iterations of the engine were renowned for running too hot, leading to premature wear and catastrophic failures.

Although not particularly popular in America, over in Europe, customers of vehicles fitted with the 1.0-liter EcoBoost engine have had their fair share of issues, primarily related to a faulty “wet belt” design. Its design causes premature wear and leads to engine failure in many vehicles.

As expected, this has resulted in widespread complaints, recalls, and investigations and the automaker has had to cover repair costs for affected customers. However, to give Ford its due, it acknowledged the problem and took steps to rectify it through design changes and extended warranties.

The Latest Recall Affecting Ford’s EcoBoost Engine Family

As the old adage goes, if it’s not one thing, it’s another—and that’s very much the case for Ford. The latest recall affecting the EcoBoost engine family has stirred concerns among owners of vehicles fitted with the powerful 2.7-liter and 3.0-liter Nano engines.

Known for their impressive power output and efficiency, these engines are under the spotlight due to a critical issue identified by the NHTSA. A recall has been issued, specifically impacting certain Ford and Lincoln models, which may be at risk of catastrophic engine failure due to a defect in the intake valves.

Ford has identified that the affected intake valves are produced using an alloy called Silchrome Lite, which can crack and break when it becomes excessively hot, leading to catastrophic engine failure. The automaker changed its production methods in October 2021 to a different alloy called Silchrome 1 and found that these failures are more likely to happen early in the engine’s life, meaning that any failures that will happen are likely to have already happened.

Signs Your Nano EcoBoost Engine May Have A Cracked Or Faulty Intake Valve

The intake valve plays a crucial role in controlling the mixture of air and fuel entering the engine’s cylinders. Signs that the Nano EcoBoost engine may have a cracked or faulty intake value include:

• Engine misfires and stalling: When the intake valve is cracked, it disrupts the proper air and fuel mixture, which can cause the engine to misfire. In some instances, rough idling or unexpected stalling may occur, which is particularly dangerous when out on the road.

• Power loss: A cracked intake valve can also lead to sudden power loss. While this will concern all owners affected by the failing EcoBoost, it’s especially concerning for owners of vehicles such as the F-150 or Bronco, which are suited to towing.

• Complete engine failure: In the most severe of cases, a cracked intake valve can lead to catastrophic engine failure. If enough air leaks through the cracked valve, it could potentially cause the engine to overheat, seize, or even fail entirely.

Models Affected By The Failing Nano EcoBoost Engine

Although there are potentially 90,736 vehicles affected by the Nano EcoBoost intake valve failure, it’s important to note that only models between 2021 and 2022 featuring either the 2.7-liter twin-turbocharged EcoBoost V-6 or the 3.0-liter turbocharged EcoBoost V-6 are affected. The models affected by the EcoBoost recall are:

• 2021-2022 Ford F-150: Trims such as the Ford F-150 XL, XLT, and Lariat are all available with the 325-horsepower 2.7-liter EcoBoost V-6.

• 2021-2022 Ford Bronco: Both the Bronco Wildtrak and First Edition come equipped with the 330-horsepower 2.7-liter EcoBoost V-6.

• 2021-2022 Ford Explorer: Ford Explorer trims like the ST, King Ranch, and Platinum all feature the 400-horsepower 3.0-liter EcoBoost V-6.

• 2021-2022 Ford Edge: The top-of-the-range Ford Edge ST boasts a 325-horsepower 2.7-liter EcoBoost V-6 engine.

• 2021-2022 Lincoln Aviator: All trims of the 2021 Lincoln Aviator boast the 3.0-liter EcoBoost V-6.

• 2021-2022 Lincoln Nautilus: The top-tier 2021 and 2022 Lincoln Nautilus Black label features a 335-horsepower 2.7-liter EcoBoost V-6.

It’s worth noting that the Bronco Raptor and F-150 Raptor aren’t affected by the potential issue. The materials used to produce intake valves look to have fixed the issue before the later release of these high-performance models.

Ford Offers A Free Extended Warranty For Peace Of Mind

Although it was originally presumed that engine failures were due to a faulty drivetrain, according to a report released by the NHTSA and the ODI (Office of Defects Investigation) regarding their investigation into EcoBoost failures, the intake valve was, in fact, the root cause of the problem.

The affected vehicles were built between May 2021 and October 2021, during which time production increased for both Ford and the company that made the intake valves. The report also states that Ford started the preliminary investigation into the engine failures, and the NHTSA then involved itself in a two-year investigation.

The investigation found that, thankfully, no reported fatalities or injuries were caused by the engine failures. However, it did find that Ford failed to implement any field of action for vehicles on the road built during the aforementioned period in 2021. The automaker has, however, rectified this, offering a 10-year/150,000-mile extended warranty for any potentially affected vehicles.

How To Check If Your Vehicle Is Affected By Ford’s EcoBoost Failures

The NHTSA has closed its investigation into Ford’s faulty EcoBoost engine. However, it’s still worth checking to see if your vehicle is affected. You may have already received some sort of communication from Ford or Lincoln if your model is affected by the recall, but if that hasn’t happened yet, or you want reassurance that you aren’t driving around in a vehicle with a potentially faulty engine, here are some steps you can take.

• Check recall status: If you visit the NHTSA website and click on the ‘Recalls’ page, you can input your vehicle’s VIN, year, make and model, or license plate. This will confirm if your vehicle has been recalled. Your VIN can be found on your vehicle’s paperwork or, more commonly, on the dashboard near the windshield on the driver’s side.

• Contact Ford or Lincoln customer service: It may not be the most enjoyable way to spend a big chunk of the day, but the Ford and Lincoln support teams are on call to assist you with any questions about the recall.

• Check your documents and keep records of inspections and repairs: When you have any questions for Ford or Lincoln, it will make life a lot easier to ascertain if your vehicle is affected by the recall.

What To Do If Your Vehicle Is Affected

It goes without saying, but if you do find that your vehicle is affected, it’s important to have it inspected by Ford or Lincoln as soon as possible. Try to limit driving as much as possible, or even better, avoid using the vehicle completely.

As previously mentioned, there are some tell-tale signs that your vehicle may already have a cracked intake valve, especially if it’s idling rough, making unusual engine sounds, losing power, or stalling. If your vehicle displays any of these signs, contact your local authorized Ford or Lincoln dealer to schedule an inspection.

The automakers are covering the cost of these inspections, which involve a detailed examination of the intake valves and related engine components. Booking an inspection as soon as possible will ensure that you won’t have to wait too long if your engine is faulty and that you don’t break down and subsequently have to wait even longer for an engine replacement if there’s a catastrophic failure.

What Ford Is Doing About EcoBoost Failures

In addition to offering the aforementioned extended warranty on affected vehicles, Ford has a comprehensive plan to address the EcoBoost intake valve issue. Should your vehicle be on the recall list, the automaker will ease any concerns you may have about its safety or fix the problem.

• Thorough valve inspections: Authorized Ford and Lincoln dealerships will inspect the intake valves of all affected 2.7-liter and 3.0-liter EcoBoost engines. Technicians will assess the valves for signs of cracking or wear, using specialized diagnostic tools to check valve function and inspect for any irregularities that could lead to problems. These inspections are at no cost to owners.

• Component replacement: If technicians find any signs of wear, cracking, or failure in the intake valves, they will replace the affected components. Ford’s protocol ensures that only certified parts are used to maintain engine integrity and prevent future failures. This process may also include any adjustments to nearby engine components to restore performance.

• Preventative maintenance adjustments: During the inspection, technicians will review and adjust engine settings or perform maintenance to re-optimize the EcoBoost engine’s performance.

• Performance testing after repairs: After undertaking any necessary repairs, technicians will thoroughly test the engine’s performance. This final step should ensure that the EcoBoost operates as it should and has no lingering issues.

Ford’s Reputation For Reliability On The Line

The last few years have seen Ford’s reliability fluctuate. In 2022, the Initial Quality study found that Ford models experienced 167 problems per 100 vehicles sold (PP100). The following year, this rose to 249 PP100, and the latest study found Ford experienced only 179 PP100, which is well below the market average of 195 PP100.

Despite this, Ford is still trailing Honda and Toyota, two automakers renowned for their vehicle reliability. It also shows that Ford has fallen behind its closest rival, GM, whose brands Buick and Chevrolet have respectably high PP100 scores of 164 and 160, respectively.

Ford Reliability Score: 3.5/5

Granted, Ford’s latest recall may have your nerves on edge, but it’s worth noting that owning one of the automaker’s models is above average in terms of reliability in the auto market, with the average being 3.0/5. RepairPal has handed Ford a reliability rating of 3.5/5 and says that, on average, it will cost you $775 a year in maintenance costs, although that’s above the market average of $652.

CarEdge says that, on average, it will cost $54,251 to own a Ford for five years. This includes depreciation, insurance, maintenance, financing charges, and fuel costs. You may think this sounds like a lot of money, and it is, but it’s still cheaper than owning a Cadillac or Chevrolet, although it’s more expensive than owning a Buick or Toyota.

Ford’s Future Reliability

Problems per 100 vehicles sold have steadily increased over the past few years across the market as a whole. In 2021, the market saw 121 PP100, in 2022 180 PP100, in 2023 186 PP100, and in 2024 195 PP100. This is largely due to the surge in EVs coming to market, featuring components that rely on newer and sometimes more complicated technology.

Despite this, Ford has seen a drop in its reported PP100, even considering its EV lineup. It does, however, highlight the need for the automaker to apply greater reliability tests as it integrates new technologies, especially into its hard-working vehicles like the Ford F-150 Lightning.

It’s imperative that Ford proactively addresses issues with rigorous testing and durable engineering. These will be central to the automaker’s future reliability, especially as it competes in a market increasingly focused on long-term durability.

The manner in which Ford has handled the EcoBoost saga should instill some confidence that it’s committed to setting things right, covering inspection costs, offering free repairs, and extending warranties. This shows a clear commitment to customer trust and a transparent approach to its quality issues.

If anything, the recall should encourage Ford to invest more in preventative measures like enhanced testing protocols, stricter part quality standards, and engineering reviews. Fingers crossed, we continue to see the PP100 in Ford models drop further, and reliability rates increase despite the growing challenges.

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