Recall 24V635 covers 90,736 2021-2022 Ford and Lincoln vehicles with Nano EcoBoost intake valves that can break. Repair is free at franchised Ford dealers.
Ford is recalling 90,736 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with 2.7L or 3.0L Nano EcoBoost engines because the engine intake valves can break while driving. A broken intake valve can cause engine failure and loss of drive power, which increases crash risk; the dealer repair is free.
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What's wrong?
Inside the 2.7L or 3.0L Nano EcoBoost engine, each intake valve opens to let air into the cylinder before combustion. It then closes and seals the cylinder so the engine can build pressure and make power. The valve is a small internal engine part, but the engine depends on it staying intact.
On affected 2021-2022 Edge, Bronco, Nautilus, Aviator, F-150, and Explorer vehicles, the intake valves can have grinding burn and hardness above specification at the third keeper groove, the notch that helps hold the valve in place. That defect can weaken the valve. If the valve breaks while driving, the engine can fail and the vehicle can lose drive power.
Before motive power is lost, the engine malfunction indicator lamp will illuminate on the cluster. Owners can also notice the vehicle running rough before the engine failure happens.
Who's affected?
Spans six Ford and Lincoln models across the 2021 and 2022 model years, all tied to the same 2.7L / 3.0L Nano intake valve.
| 2021 Ford Edge | Hard parts internal/mechanical |
|---|---|
| 2021 Ford Bronco | Hard parts internal/mechanical |
| 2021 Lincoln Nautilus | Hard parts internal/mechanical |
| 2022 Ford Edge | Hard parts internal/mechanical |
| 2022 Ford Bronco | Hard parts internal/mechanical |
| 2022 Lincoln Nautilus | Hard parts internal/mechanical |
| 2021 Lincoln Aviator | Hard parts internal/mechanical |
| 2021 Ford F-150 | Hard parts internal/mechanical |
| 2022 Ford Explorer | Hard parts internal/mechanical |
| 2022 Lincoln Aviator | Hard parts internal/mechanical |
| 2022 Ford F-150 | Hard parts internal/mechanical |
| 2021 Ford Explorer | Hard parts internal/mechanical |
| Units affected | 90,736 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific vehicle.
What's the safety risk?
A loss of drive power increases the risk of a crash, especially if the vehicle slows in traffic. If the engine malfunction indicator lamp comes on or the vehicle runs rough, pull over when safe and arrange service before continuing. Repair is free at any franchised Ford dealer.
What should I do?
- Check your VIN to confirm your 2021-2022 Ford Edge, Bronco, F-150, Explorer, Lincoln Nautilus, or Lincoln Aviator is included in this recall.
- Contact a franchised Ford dealer to schedule the free engine cycle test that checks for intake-valve breakage and engine failure.
- Bring the recall notice if Ford mailed one. Reference recall number 24V635 and Ford recall 24S55 when you call.
- Drive cautiously until the repair is complete. Loss of drive power increases crash risk.
- Ask Ford customer service at 1-866-436-7332 about next steps if the dealer cannot schedule the inspection promptly.
What happens at the repair
At the dealer, a Ford technician performs an engine cycle test to check whether the engine covered by the recall needs replacement. If the test shows the engine is affected, the dealer replaces the engine. The recall repair is free, including parts and labor. If you already paid out of pocket for this engine repair before the recall notice, Ford's standard reimbursement plan covers eligible documented expenses. Bring your repair invoice and payment records to the service desk, or contact Ford customer service to ask how to submit the claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 23, 2024 | NHTSA published the recall |
|---|---|
| September 30, 2024 | Dealer notification began |
| September 30, 2024 | Dealer notification ended |
| October 7, 2024 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| October 7, 2024 | Interim owner notification (was planned for this date) |
| July 3, 2025 | Owner notification mailed |
Frequently asked questions
What is recall 24V635?
Recall 24V635 covers 90,736 2021-2022 Ford Edge, Bronco, F-150, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles with 2.7L or 3.0L Nano EcoBoost engines. The intake valves can break while driving, causing engine failure and a loss of drive power. Ford dealers will test the engine and replace it if needed for free.
What should I do if my 2021-2022 Ford Edge, Bronco, F-150, Explorer, Lincoln Nautilus, or Lincoln Aviator is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 24V635. If it is, contact a franchised Ford dealer to schedule the engine cycle test. Reference recall 24V635 or Ford recall number 24S55 when you call. The 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 cycle test and replace the engine if the test shows replacement is needed, free of charge.
What is the safety risk?
The safety risk is loss of drive power while driving. NHTSA campaign 24V635 says that loss of drive power increases crash risk. If your VIN is included, schedule the free dealer repair and ask Ford service what driving guidance applies before your appointment.
When were owners notified about recall 24V635?
Ford mailed owner notification letters on July 3, 2025. A used vehicle owner or anyone who missed the letter still gets the free repair if the VIN is included. Ford customer service is available at 1-866-436-7332.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/24V635000 |
|---|---|
| Ford customer service | 1-866-436-7332 |
| NHTSA recall # | 24V635 |
| NHTSA recall # (full) | 24V635000 |
Source documents
-
Download Quarterly Report (PDF) - Download Owner Notice (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
- Download Recall Report (PDF)
- Download Misc. Document (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 →