Ford recalled 90,736 vehicles in the United States because an engine intake valve could fracture, potentially causing sudden engine damage and a loss of drive power.
The National Highway Traffic Safety Administration assigned campaign number 24V-635 to the action, which Ford identified as recall 24S55. The population included certain 2021 and 2022 Ford Bronco, F-150, Edge and Explorer vehicles and Lincoln Nautilus and Aviator vehicles equipped with 2.7-litre or 3.0-litre Nano EcoBoost engines.
What could happen inside the engine
Ford’s filing said some intake valves may not have met material specifications and could become brittle. A valve that fractures can fall into the cylinder and cause catastrophic engine damage. A driver may notice rough running, unusual noise or a warning light before failure, but the recall addresses the possibility that motive power could be lost while driving.
A loss of drive power can increase crash risk, particularly in fast traffic or at an intersection. At the time of the recall filing, Ford reported no known accidents or injuries attributed to the condition. That does not mean owners should wait for symptoms before checking whether the campaign applies.
Vehicles and production period
The campaign was limited by engine type and manufacturing date, so not every vehicle bearing one of the listed model names was included. NHTSA’s documents identify affected production from the 2021 and 2022 model years and explain that Ford used engine-cycle data and manufacturing records to define the population.
Owners should enter the full VIN at NHTSA’s recall site or Ford’s support site. A model-and-year list is a screening tool, whereas the VIN result indicates whether the manufacturer currently records an open remedy for the individual vehicle.
Inspection and free remedy
Dealers were directed to perform an engine-cycle test intended to identify vulnerable engines. If the test did not meet the prescribed threshold, the engine would be replaced without charge. Recall notices and dealer records should be kept because the repair status follows the vehicle when it is sold.
NHTSA records later showed that more than 45,000 vehicles had been remedied by January 2026, while thousands of owners remained unreachable. Those figures change as repairs are completed and should not be used to infer the present status of a particular VIN.
Warranty and continuing responsibilities
Materials connected with the federal investigation also described extended coverage for the relevant engine condition, generally to the earlier of ten years or 150,000 miles under the programme’s terms. Owners should confirm coverage with Ford because eligibility depends on the VIN, service history and the exact campaign rules.
A recall repair is a safety action, not routine paid maintenance. An owner should not be charged for the specified remedy at an authorised dealer. If a dealer disputes eligibility despite an open VIN result, the owner can contact Ford and NHTSA with the campaign number and written service response.
This campaign is separate from Ford’s Maverick rear-view-camera recall, even though the two actions were announced close together. Combining unrelated recalls can lead an owner to request the wrong repair, so campaign numbers should always accompany the vehicle description.
Source: NHTSA recall 24V-635. Ford’s manufacturer reference is 24S55.
