Ford Bronco Engine Failures Stem From Two Problem Areas: Report

It isn’t just faulty valves causing Ford Bronco engine failures, as another design flaw is contributing to the problem.

While the launch of the all-new, sixth-generation 2021 Ford Bronco has been one mired with issues amid a pandemic, resulting global supply chain issues, and hardtop production woes, the beloved SUV’s return has otherwise been a celebrated one. However, a new problem has begun to rear its ugly head in recent months in the form of a few 2.7-liter EcoBoost V6 engine failures, which has prompted those owners to petition the National Highway Traffic Administration (NHTSA) to open an investigation into the matter. Now, Ford Authority is reporting that there are actually two problem areas causing these Ford Bronco engine failures, too – which have previously been attributed solely to faulty valves.

Those valves are indeed an issue when it comes to Ford Bronco engine failures, as Ford Authority notes that those particular components were acquired from a new supplier for use in the Bronco but are cheap and lower quality as a result. Making matters worse, the supplier didn’t properly validate the valves, but that isn’t the only thing contributing to these 2.7L EcoBoost engine failures.

Turns out, the oil pans used in this application are poorly designed as well, as the oil pickup tube can become uncovered during hard driving . This can lead to damaged valves and bearings, all of which are issues that Ford Explorer ST owners have previously experienced as well with the 3.0-liter EcoBoost V6, a larger-displacement version of the 2.7.

So far, a total of 32 Bronco owners have filed complaints with the NHTSA regarding engine failures, though Ford estimates that 25,538 vehicles may ultimately be affected. The agency has already opened an inquiry into the matter and will now decide if a recall is warranted, but in the meantime, those affected have faced a loss in drive power while moving at highway speeds, after which the vehicle won’t restart due to engine failure.

“We are aware of a select number of engines with this concern and we are investigating,” Ford said in a statement. “If any customers are experiencing issues, they will be covered under the vehicle’s five-year/60,000-mile powertrain warranty. We will cooperate with the NHTSA as we always do.”

Photos: Ford

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Brett Foote

Brett Foote has been covering the automotive industry for over five years and is a longtime contributor to Internet Brands’ Auto Group sites, including Chevrolet Forum, Rennlist, and Ford Truck Enthusiasts, among other popular sites.

He has been an automotive enthusiast since the day he came into this world and rode home from the hospital in a first-gen Mustang, and he's been wrenching on them nearly as long.

In addition to his expertise writing about cars, trucks, motorcycles, and every other type of automobile, Brett had spent several years running parts for local auto dealerships.

You can follow along with his builds and various automotive shenanigans on Instagram: @bfoote.