Ford has been under scrutiny due to widespread engine failures in its 2.7-liter and 3.0-liter EcoBoost engines, prompting an investigation by the National Highway Traffic Safety Administration (NHTSA). Reports surfaced of intake valves breaking and dropping into the combustion chamber, causing catastrophic engine damage and leaving drivers stranded with non-functioning vehicles.
After months of investigation, Ford has announced a recall affecting over 90,000 vehicles but has stopped short of replacing all affected engines outright. Instead, the company is implementing a 10-year, 150,000-mile extended powertrain warranty for at-risk vehicles.
If you own a 2021-2022 Ford Bronco, F-150, Edge, Explorer, Lincoln Nautilus, or Lincoln Aviator, you may be affected by this recall. While Ford claims that most failures have already occurred, some vehicles may still be at risk. If your vehicle has suffered repeated engine issues—or if you continue to experience problems after recall repairs—you may have legal options under California’s Lemon Law.
At The Barry Law Firm, we specialize in helping California consumers take action against automakers when their vehicles fail to perform as promised. If your Ford or Lincoln has had persistent engine issues, you may be entitled to a refund, replacement vehicle, or financial compensation.
What’s Wrong with the Ford EcoBoost Engines? 
Ford’s 2.7-liter and 3.0-liter EcoBoost engines, which are found in multiple 2021–2022 Ford and Lincoln models, have been linked to serious and potentially catastrophic failures. These issues prompted an investigation by the National Highway Traffic Safety Administration (NHTSA) after reports surfaced of sudden engine failure, power loss, and the inability to restart the vehicle.
At the heart of the problem is a manufacturing defect in the intake valves, which can cause engine components to break apart while driving, leading to extensive internal damage and costly repairs.
What Is Causing These Engine Failures?
Ford has identified that the issue originates from improperly machined intake valves that were produced incorrectly during manufacturing. These defective valves were subjected to excessive grinding, which altered the structure of the metal and made them significantly weaker.
The defect creates a high risk of valve breakage, leading to:
- Valve Fragmentation: The intake valve can fracture at the keeper groove, where it is held in place, due to hardening caused by excessive grinding.
- Valve Drop Into the Combustion Chamber: Once the valve breaks, fragments of metal can fall into the engine’s combustion chamber, creating a chain reaction of mechanical failure.
- Piston and Cylinder Wall Damage: The loose metal fragments collide with the pistons and cylinder walls, often resulting in complete engine destruction.
What Happens When the Valve Fails?
When an intake valve breaks, it can lead to sudden and severe engine failure. Ford owners have reported experiencing:
- Complete Loss of Power While Driving – The vehicle suddenly stalls without warning, creating a dangerous situation, especially at highway speeds.
- Permanent Engine Damage – The broken valve fragments can destroy internal engine components, requiring a full engine replacement.
- Unresponsive Restart Attempts – Once the damage occurs, the vehicle cannot be restarted, leaving drivers stranded.
- Expensive Out-of-Pocket Repairs – If not covered by Ford’s recall, engine replacement costs can exceed $10,000, a significant financial burden for vehicle owners.
This issue does not develop gradually—it often occurs suddenly and without warning. Drivers have reported that their vehicles were functioning normally until the engine completely failed within seconds, leaving them unable to continue driving.
How Widespread Is This Issue?
Ford has acknowledged that the problem affects at least 90,000 vehicles, but the true number may be even higher. The company has already processed:
- 825 warranty claims related to this issue.
- 936 full engine replacements due to intake valve failure.
Some experts believe that not all defective engines have failed yet, meaning many more vehicles could still be at risk.
Did Ford Fix the Problem in Newer Models?
Yes. Ford changed the metal alloy used in the intake valves starting in October 2021, which means that engines built after this date are not affected by the issue. However, vehicles built before this change—many of which are still on the road—remain at risk.
Even though Ford has acknowledged the problem and issued a recall, it has not committed to automatically replacing all affected engines. Instead, Ford is offering dealership tests to determine whether an engine is at risk and providing a 10-year, 150,000-mile extended warranty to owners as a safety net.
While Ford’s response is meant to reassure consumers, it does not guarantee that all vehicles will be fixed before failure occurs. If your 2021-2022 Ford or Lincoln is experiencing engine performance issues, unusual noises, or sudden power loss, you should seek repairs immediately and consider your legal rights under California’s Lemon Law.
If your Ford has already undergone multiple repairs—or if you experience engine failure despite Ford’s extended warranty—The Barry Law Firm can help you determine whether you have a valid Lemon Law claim.
What If Engine Issues Persist After Recall Repairs? 
Ford’s recall process involves testing vehicles at dealerships to determine if an engine replacement is necessary. However, this does not guarantee that all defective engines will be replaced. If your vehicle passes Ford’s test, it may still have underlying issues that could surface later.
Common Problems That May Persist After Recall Repairs
Even if Ford does not replace your engine immediately, your vehicle could still experience:
- Loss of power or intermittent stalling – Your vehicle may still hesitate or shut down unexpectedly.
- Check engine lights related to valve issues – Even if Ford does not replace your engine now, problems could emerge over time.
- Unusual noises from the engine – Clicking, knocking, or rattling sounds may indicate ongoing mechanical failure.
- Decreased fuel efficiency – A malfunctioning engine may consume more fuel than normal, reducing performance.
- Recurring misfires and rough idling – Your vehicle may shake or struggle to maintain a steady RPM.
Ford claims that most defective valves fail within the first few thousand miles, but this is not always the case. Some engines may not exhibit symptoms until tens of thousands of miles later, at which point the damage could be even more severe.
If your Ford or Lincoln continues to have issues despite passing recall tests, you may still qualify for a Lemon Law claim in California.
What Are Your Options Under California’s Lemon Law?
If your vehicle has had multiple repair attempts for the same engine problem, you may be eligible for:
- A full refund of your purchase price
- A replacement vehicle of similar value
- Cash compensation for loss of vehicle value
Many consumers assume that a recall automatically resolves the issue, but that’s not always the case. If your vehicle continues to experience problems, you may have legal options beyond what Ford is offering.
At The Barry Law Firm, we will never charge you, no matter the outcome of your case. Contact us today for a FAST and FREE consultation to discuss your legal options.
How The Barry Law Firm Can Help
At The Barry Law Firm, we specialize in helping California consumers take legal action against manufacturers when their vehicles fail to meet quality and safety standards. If your Ford or Lincoln has been in the shop repeatedly for engine issues, you may be entitled to a refund, replacement, or cash compensation under California’s Lemon Law.
Why Work with The Barry Law Firm?
- Lemon Law Experts – We specialize in California Lemon Law cases and know how to hold manufacturers accountable.
- No Upfront Costs – At The Barry Law Firm, we will never charge you, no matter the outcome of your case. Ford is responsible for covering all legal fees if we win your case.
- Proven Success – We have helped thousands of consumers obtain favorable settlements for their defective vehicles.
- Personalized Attention – We handle all legal paperwork and negotiations so you don’t have to deal with the stress.
If Ford’s recall has not fully resolved your vehicle’s engine issues, we can help you take legal action to secure the compensation you deserve.
Closing
Ford’s EcoBoost engine failures have left thousands of owners dealing with unexpected breakdowns, expensive repairs, and repeated trips to the dealership. While Ford’s 10-year, 150,000-mile extended warranty provides some peace of mind, it does not guarantee that affected vehicles won’t experience engine failure in the future.
If your 2021-2022 Ford or Lincoln vehicle has been recalled but continues to have engine problems, California’s Lemon Law may provide additional protections. You should not have to deal with ongoing repairs, loss of vehicle value, or an unsafe car.
At The Barry Law Firm, we are committed to helping consumers hold manufacturers accountable when they fail to deliver reliable vehicles. We offer FAST & FREE consultations and, at The Barry Law Firm, we will never charge you, no matter the outcome of your case.
Don’t wait—California’s Lemon Law has strict deadlines. Contact The Barry Law Firm today to discuss your case and find out if you qualify for a refund, replacement vehicle, or cash compensation.
Call 877-536-6603 or visit mylemonrights.com to schedule your FAST & FREE consultation.
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