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The NHTSA is investigating new cases of “catastrophic engine failure,” in the new Ford Bronco SUV with the 2.7-liter EcoBoost engine.  According to the new NHTSA complaint, the alleged defect is in the engine’s valves, and that 2021 model year Ford Broncos are experiencing “loss of motive power at highway speeds with no-restart due to catastrophic engine failures.” The U. S. Department of Transportation’s National Highway Traffic Safety Administration opened the investigation on May 27.

According to the NHTSA: “Under normal driving conditions without warning the vehicle may experience a loss of motive power without restart due to catastrophic engine failure related to a faulty valve within 2.7 L Eco-Boost Engines.” Catastrophic failure certainly sounds bad, and a bad valve in an engine can cause that problem in a Ford Bronco.

What are the problems with the new Ford Bronco?

The Ford Bronco Raptor has more power than expected, but the NHTSA is investigating problems with catastrophic engine problems.
2022 Ford Bronco Raptor | Ford

The NHTSA opening an investigation is a far cry from issuing a recall. In this case, there are only 32 complaints of Ford Bronco problems related to valves. In April Ford said it has sold more than 36,000 Broncos year-over-year. Of those, the NHTSA says more than 25,000 are in the “population” of Broncos with this specific motor, so the percentage of failures is pretty small. No fires, injuries, or accidents were reported to the NHTSA. Also, the NHTSA does not give the dates of the failures.

Are there other engine problems with the Bronco?

The new Ford Bronco problems include bad valves in a small percentage of motors.
2022 Ford Bronco Raptor | Ford

This isn’t the first time that Ford Bronco 2.7-liter EcoBoost V6 engines have had problems. In May, it was reported that the engines were having issues with the valvetrain, killing the motors. The first reports started coming last year when some people had similar issues with their 2021 Broncos. The Bronco also can come with a smaller, 300-horsepower, 2.3-liter EcoBoost engine. The 2.7-liter is a V6 that is popular in Ford’s F-150 and it makes up to 330 horsepower in the Bronco.

What’s the fix? Replace the motor. But, they should be covered under Ford’s 60,000-mile powertrain warranty. A Ford spokesman told CNET the company is aware of the issue and that any issues will be covered under the warranty. Ford already addressed issues with some Bronco roofs.

How much does a 2022 Bronco cost?

A red 2022 Ford Bronco Wildtrak model with option HOSS 3.0 parked on a snowy off-road trail in a forest
2022 Ford Bronco Wildtrak | The Ford Motor Company

The 2022 Bronco starts at $30,800. But good luck finding one. They’re a super-popular, super-capable, SUV. The 2022 Bronco is no longer available for order from Ford and they’re selling for a premium on used car websites. Regardless, owners say they are satisfied with their Broncos. Ford is also offering two special edition Broncos, the Bronco Raptor and the Bronco Everglades. The Raptor version has special Fox shocks and 37-inch tires that allow it to bound over desert terrain. The Everglades has a Warn brand winch and a snorkel that allows it to go through deeper water than standard versions.

The Bronco Sport is a separate model that is based on the Ford Escape.

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Writer - Sedans & Coupes

Dan Mayfield

Dan joined MotorBiscuit in 2022 with over 20 years of experience in journalism and a lifelong passion for anything related to the automotive industry. He grew up wrenching a 1949 Ford pickup truck and an MGB with his dad, learning how not to wire a fuel pump (he inadvertently set the MGB on fire).

After earning a bachelor’s degree in photojournalism from the University of New Mexico, Dan has contributed his expertise to a range of local outlets, including the City of Albuquerque, US Eagle, and the Alliance for Local Economic Prosperity.

On weekends, Dan spends Saturdays enjoying “cars and coffee” chats and, on Sundays, he’s watching the Route 66 Cruise roll through town. He also races motorcycles, and it’s not unusual to find him elbows-deep in his latest cafe racer build.

Taking advantage of the local desert terrain, Dan also enjoys exploring and driving off-road in his trusty Ram Rebel pickup truck, which provides personal insights into his contributions to our Trucks, SUVs, & Crossovers coverage. Dan strives to give our readers unique information about the dynamic automotive market, reading anything that has to do with cars, trucks, bikes, 4X4s, and, in his words, “everything with a motor.”

Dan has earned a number of accolades from the Public Relations Society of America, and is a University of Southern California, Annenberg School of Communication and Journalism Fellow.