Recall 22V454 covers 776 2022 Ford Explorer and Lincoln Aviator vehicles with improperly heat-treated engine rails. Free repair once available at franchised Ford dealers.
Ford is recalling 776 2022 Explorer and Lincoln Aviator vehicles because improperly heat-treated engine rails can reduce crash protection and fail federal occupant-protection and fuel-system standards. An engine rail can also detach and contact the road while driving, which increases crash risk; the dealer repair will be free once Ford makes it available.
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What's wrong?
The engine rail sub-assembly in the 2022 Explorer and Aviator is part of the front structure that ties the engine area to the front subframe. It helps keep the front of the vehicle aligned under normal driving loads and helps the structure perform as designed in a crash.
On affected vehicles, the aluminum rails went through an unapproved e-coat stripping repair at a supplier. The oven process annealed the aluminum, which means the metal was softened by heat and no longer met Ford's yield strength requirement. A softened rail can loosen from the front subframe instead of staying fixed where it belongs.
Owners can hear a clunking noise during acceleration, deceleration, or after hitting a pothole, speedbump, or similar road surface. That noise is the warning sign Ford identified before the rail loosens further.
Who's affected?
Includes Explorer and Aviator SUVs, with the same engine rail sub-assembly tied to engine and structure components.
| 2022 Ford Explorer | Engine |
|---|---|
| 2022 Ford Explorer | body or structural component |
| 2022 Lincoln Aviator | Engine |
| 2022 Lincoln Aviator | body or structural component |
| Units affected | 776 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific SUV is included.
What's the safety risk?
Improperly heat-treated engine rails can reduce structural protection in a crash and increase injury risk. A loose rail can also contact the road while driving and raise crash risk. Listen for a clunk during acceleration, deceleration, or after a pothole or speedbump. Repair will be free at any franchised Ford dealer once available.
What should I do?
- Check your VIN to confirm your 2022 Ford Explorer or Lincoln Aviator is included in this recall.
- Call Ford customer service at 1-866-436-7332 to confirm current repair instructions before scheduling dealer work.
- Reference recall number 22V454 and Ford recall 22C13 when you call or speak with the dealer.
- Bring the owner notice Ford mailed if you have it.
- Avoid hard driving until the vehicle is inspected because improperly heat-treated engine rails can reduce crash protection or detach while driving.
- Ask about the free engine-rail strength test that checks the crash-structure rails, plus rail replacement, vehicle replacement, or buyback if Ford's inspection requires it.
What happens at the repair
Ford has identified the dealer process, but the remedy is still listed as under development. Once Ford opens the repair, a Ford technician will perform an engine rail strength test and replace the rails if the test shows replacement is needed. The final dealer repair will be free once available. If the rails require replacement, Ford says owners will have the option of a vehicle replacement or buyback. Ford's standard reimbursement plan covers eligible owner-paid remedy costs from before the recall notice period. Ask Ford customer service or the dealer how to submit prior repair paperwork under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| June 24, 2022 | NHTSA published the recall |
|---|---|
| June 27, 2022 | Dealer notification began |
| June 27, 2022 | Dealer notification ended |
| August 1, 2022 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| August 1, 2022 | Interim owner notification (was planned for this date) |
| August 22, 2022 | Owner notification mailed |
Frequently asked questions
What is recall 22V454?
Recall 22V454 covers 776 2022 Ford Explorer and Lincoln Aviator vehicles with engine rails that were improperly heat-treated. The defect affects crash structure and fuel-system integrity standards. Ford dealers will test the engine rail strength and replace the rails as needed for free.
What should I do if my 2022 Ford Explorer or Lincoln Aviator is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 22V454. If it is, contact a franchised Ford dealer and ask for the engine rail strength test under Ford recall number 22C13. The dealer repair is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. Ford dealers will perform the engine rail strength test for free and replace the rails as needed. If replacement is required, Ford says owners have the option for a vehicle replacement or buyback.
What is the safety risk?
The safety risk is reduced structural protection in a crash, which increases injury risk. An engine rail also can detach and contact the road while driving, increasing crash risk. If your VIN is included, schedule the dealer inspection and repair path.
When were owners notified about recall 22V454?
Ford mailed owner notification letters on August 22, 2022. If you bought the vehicle used or never received a letter, check your VIN to confirm whether your 2022 Explorer or Aviator is included, then reference recall 22V454 or Ford recall number 22C13 when calling the dealer.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/22V454000 |
|---|---|
| Ford customer service | 1-866-436-7332 |
| NHTSA recall # | 22V454 |
| NHTSA recall # (full) | 22V454000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Recall Document (PDF) (PDF)
- Download Quarterly Report (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Owner Notification Letter (PDF)
- Download Misc. Document (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →