Ford recall 24V-635 covers about 90,736 2021 and 2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus and Lincoln Aviator models with the 2.7-liter or 3.0-liter EcoBoost built in a short 2021 window, because intake valves can crack and break and wreck the engine. The dealer counts the engine's lifetime cycles, runs a high-rpm test if the count is low, and replaces the engine if it fails. If the used truck or SUV you are eyeing is on the list, the good news is that NHTSA's data says most bad valves fail early, often before 5,000 miles. A car that has made it well past 20,000 is a lot less scary, but it still needs the test.
We pulled Ford's Part 573 report, the owner letter and NHTSA's closing report from its engineering analysis on November 8, 2026. Sounds dry, but the closing report has the most useful buying detail in the whole pile, so stick with us.
Which vehicles
Ford's report breaks it down like this:
- 2021 to 2022 Ford F-150 with the 2.7-liter: 47,719.
- 2021 to 2022 Ford Bronco with the 2.7-liter or 3.0-liter: 15,835, built May 1 to October 30, 2021.
- 2021 to 2022 Ford Explorer with the 3.0-liter: 14,262, built June 7 to October 31, 2021.
- 2021 to 2022 Lincoln Aviator with the 3.0-liter: 7,199.
- 2021 to 2022 Lincoln Nautilus with the 2.7-liter: 3,355.
- 2021 to 2022 Ford Edge with the 2.7-liter: 2,366.
Ford says the vehicles were not built in VIN order, and it estimates about 1 percent have the defect. So a neighbor's Bronco built the same week tells you nothing about yours. Run the specific VIN.
Notice what is not on the list, too. The F-150 entry is only the 2.7-liter, so a 3.5-liter EcoBoost or 5.0-liter V8 truck is outside this recall. The Explorer entry is only the 3.0-liter, which leaves out the 2.3-liter four. Sellers mix these up constantly, and so do some listing sites, so pop the hood or check the window sticker if you can get one.
What goes wrong
The valves in question are Ford's "Nano" intake valves, part number JT4E-6507-AB, from Eaton's plant in Kearney, Nebraska. Ford says they may have grinding burn and hardness beyond spec at the third keeper groove. When one breaks, the result can be catastrophic engine damage and a loss of motive power. The warning, per Ford, is a check engine light and rough running before power drops off.
NHTSA's investigation started with a 2021 Bronco 2.7-liter defect petition in July 2022 and grew into an engineering analysis, EA23002, covering 411,315 vehicles. It turned up 1,066 unique vehicles with failures, 825 warranty claims and 936 engine exchanges. Failures clustered in vehicles built in a "spike period" of May to October 2021, which ended with production changes including a switch in valve alloy from Silchrome Lite to Silchrome 1.
Why mileage matters here
This is the piece buyers should care about. NHTSA's closing report says the vast majority of failures happened before 20,000 miles, and over half before 5,000. The failure rate has been falling since November 2021, and NHTSA's statistical work agreed with Ford's view that most vehicles with bad valves have probably already failed.
So a 2021 Bronco with 45,000 miles and no engine trouble is not the same risk as one with 6,000 miles that sat in a garage. The low-mile garage queen, which usually looks like the better buy, is actually the one that has not proven itself yet. Irritating, but that is how this defect behaves.
What the dealer does, and coverage
The dealer checks the cumulative engine cycles. If the vehicle is under Ford's threshold, it runs a high-rpm cycle accumulation procedure meant to flush out a weak valve. If the engine fails, it gets replaced, and replacement engines use in-spec valves. Ford's owner letter says the job takes less than half a day, and that Ford has not told owners to stop driving. Per NHTSA's recall summary, owner letters for the remedy went out July 3, 2025. Ford's number is 24S55.
Ford also told NHTSA it would run customer satisfaction campaign 24N12, extending coverage to 10 years or 150,000 miles, whichever comes first. Ask the dealer whether that applies to the specific VIN, since a satisfaction campaign is not the same thing as a recall. If a previous owner paid for a new engine, the letter says refunds apply only to engine long block replacement, and the recall still has to be done anyway.
Checking a used one
- Run the VIN through Ford's or NHTSA's lookup. Our Ford recall check covers both.
- Ask for the 24S55 repair order. If the engine was replaced, that is a good thing.
- On a test drive, any misfire, flashing light or rough idle is a no until a Ford dealer looks at it.
- Read the model guide: Bronco, F-150, Explorer, Edge or Aviator.
The same engines have another known issue, so read our EcoBoost coolant intrusion guide too. And if you are curious how campaigns like 24N12 work, our piece on goodwill and secret warranties explains the difference.
About history reports
A history report will not tell you whether a valve is cracked. It can show an engine replacement if a dealer reported it, plus title and accident history. CARFAX sells single reports for roughly $39.99 to $44.99. CarVins resells CARFAX and AutoCheck under license and has no affiliation with CARFAX, AutoCheck or Experian. Lately a guest report runs about $5.50, a member report about $4.50, and both together about $6.75, but please confirm at checkout since prices do change.
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