CSR

Lincoln · NHTSA safety record

2021 Lincoln Aviator

Every safety complaint, recall and defect investigation the US government holds on this vehicle.

38

Complaints

1

Crashes

1

Fires

2

Injuries

0

Deaths

Owners of the 2021 Lincoln Aviator have filed 38 safety complaints with NHTSA between March 2022 and July 2026. The most complained-about system is the electrical system, named in 11 of them (29%). The typical failure was reported at 60,000 miles, the median across the 8 complaints that gave an odometer reading.

NHTSA has issued 28 recalls covering this vehicle.

Recalls (28)

SEATS:MID/REAR ASSEMBLY

26V451000 · July 14, 2026

The defect
Ford Motor Company (Ford) is recalling certain 2020-2027 Aviator and 2020-2026 Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, tipping, or sliding unexpectedly.
The risk
A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing the risk of injury.
The remedy
Dealers will inspect and replace the bezel around the switch as necessary, free of charge. Interim letters explaining the safety risk are expected to be mailed July 27, 2026. Additional letters will be sent once the remedy is available, anticipated in January 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S52. This recall expands Recall 25V393. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on July 16, 2026.

Ford Motor Company · up to 387,911 vehicles across all model years covered

POWER TRAIN:AUTOMATIC TRANSMISSION

26V402000 · June 24, 2026

The defect
Ford Motor Company (Ford) is recalling certain 2018-2021 Navigator, Expedition, 2020-2021 Explorer, Lincoln Aviator, and 2021 F-150 vehicles. The transmission park pawl may engage while the vehicle is in motion, resulting in park system damage.
The risk
Park system damage may result in a vehicle rollaway, increasing the risk of a crash.
The remedy
Dealers will update the powertrain control module software, and inspect and replace any damaged transmission components as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed July 10, 2026. Additional letters will be sent once the remedy is available, anticipated in April 2027. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S48. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on June 26, 2026.

Ford Motor Company · up to 741,195 vehicles across all model years covered

SEAT BELTS

26V159000 · March 17, 2026

The defect
Ford Motor Company (Ford) is recalling certain 2020-2026 Explorer and Lincoln Aviator vehicles. The seat belt anchor bolts at the second-row outer seating positions may be improperly secured.
The risk
A loose seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.
The remedy
Dealers will inspect the second-row outer seat belt lower anchor bolts and replace or repair them as necessary, free of charge. Owner notification letters were mailed March 30, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C18. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 19, 2026.

Ford Motor Company · up to 561 vehicles across all model years covered

BACK OVER PREVENTION:SOFTWARE

26V123000 · March 3, 2026

The defect
Ford Motor Company (Ford) is recalling certain 2020-2022 Escape, Lincoln Corsair, 2020-2024 Lincoln Aviator, and Explorer vehicles. The image on the center display may flip or invert, resulting in an incorrectly displayed rearview image when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
The risk
An incorrectly displayed rearview image can reduce the driver’s view behind the vehicle, increasing the risk of a crash.
The remedy
Dealers will update the accessory protocol interface module (APIM) software, free of charge. Owner notification letters were mailed June 23, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26C11. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 5, 2026.

Ford Motor Company · up to 889,950 vehicles across all model years covered

VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

26V117000 · March 3, 2026

The defect
Ford Motor Company (Ford) is recalling certain 2020-2022 Explorer, Escape, Lincoln Aviator, and Lincoln Corsair vehicles. The windshield wiper motor may fail and prevent the windshield wipers from operating properly.
The risk
Windshield wipers that fail to operate properly can reduce visibility, increasing the risk of a crash.
The remedy
Dealers will inspect and replace the front wiper motors as necessary, free of charge. Interim letters, notifying owners of the safety risk, were mailed April 2, 2026. Additional letters will be sent once the final remedy is available, anticipated in October 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 26S14. Vehicle Identification Numbers (VINs) involved in this recall became searchable on NHTSA.gov on March 4, 2026.

Ford Motor Company · up to 604,533 vehicles across all model years covered

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

25V455000 · July 7, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2021-2023 Bronco, Explorer, Lincoln Aviator, F-250 SD, F-350 SD, F-450 SD, F-550 SD, 2021-2022 Lincoln Navigator, Mustang, F-150, and 2022 Expedition vehicles. The low-pressure fuel pump may fail, which can result in an engine stall while driving.
The risk
An engine stall increases the risk of a crash.
The remedy
Dealers will replace the low pressure fuel pump on super duty vehicles and update the powertrain control module (PCM) software on all other affected vehicles, free of charge. Owner notification letters were mailed July 27, 2026. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S75.

Ford Motor Company · up to 850,318 vehicles across all model years covered

BACK OVER PREVENTION:SOFTWARE

25V442000 · June 27, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2018-2022 Transit Connect, 2019-2020 MKZ, MKX, Edge, Continental, F-150, Nautilus, Fusion, 2019-2023 Ranger, Mustang, 2020-2021 EcoSport, Expedition, Navigator, 2020-2022 Escape, F-250 SD, Corsair, 2020-2023 Aviator, Transit, 2020-2024 Explorer, 2021-2024 Bronco Sport, and 2022-2024 Maverick vehicles. A software error may cause the rearview camera to display a blank image, or the image may remain on the display after the backing event has ended.
The risk
A rearview camera that displays a blank image can reduce the driver's view behind the vehicle. A rearview image that continues to be displayed after the vehicle is shifted out of reverse may distract the driver. Both of these situations can increase the risk of a crash.
The remedy
Dealers will update the rearview camera software, free of charge. Owner notification letters were mailed September 4, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S72.

Ford Motor Company · up to 200,237 vehicles across all model years covered

STRUCTURE:BODY

25V407000 · June 13, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator vehicles. The rear door window bars and C-pillar trim may have insufficient adhesive bonding, which can allow the trim to detach from the vehicle.
The risk
Detached trim may cause a road hazard and increase the risk of a crash.
The remedy
Dealers will repair or replace C-pillar appliques and window division bars, free of charge. Owner notification letters were mailed September 29, 2025. Owners may contact Ford Customer Service at 1-866-436-7332. Ford's number for this recall is 25S66.

Ford Motor Company · up to 132,914 vehicles across all model years covered

SEATS:MID/REAR ASSEMBLY

25V393000 · June 13, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2025 Aviator, and Explorer vehicles. The switch for the easy-entry second-row outer seats may bind or stick, resulting in the seats unlatching, folding, or sliding unexpectedly while driving.
The risk
A seat that moves unexpectedly may not properly restrain an occupant during a crash, increasing their risk of injury.
The remedy
Dealers will inspect the second-row seat switch, and replace the bezel around the switch as necessary, free of charge. Owner notification letters were mailed August 7, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S67.

Ford Motor Company · up to 304,662 vehicles across all model years covered

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

25V349000 · May 23, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Lincoln Aviator vehicles equipped with 3.0L PHEV engines that were repaired incorrectly under recall 23V626. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.
The risk
Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
The remedy
Dealers will update the Battery Energy Control Module software, free of charge. Owner notification letters were mailed June 26, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S58.

Ford Motor Company · up to 8 vehicles across all model years covered

SEAT BELTS:FRONT:WARNING LIGHT/DEVICES

25V338000 · May 23, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator and Lincoln Corsair vehicles equipped with a Revel Audio System that were repaired incorrectly under recall 22V-953. When the driver's seat belt is not buckled and the vehicle is started, the seat belt warning system may activate the audible warning chime for an insufficient amount of time of less than 4 seconds. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
The risk
An audible warning chime that does not properly alert of an unbelted seat belt can increase the risk of injury during a crash.
The remedy
Dealers will update the audio control module software, free of charge. Owner notification letters were mailed July 3, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25C18.

Ford Motor Company · up to 4,442 vehicles across all model years covered

BACK OVER PREVENTION:SOFTWARE

25V159000 · March 14, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles previously repaired incorrectly under recall number 23V-342. The video output may fail, preventing the rearview camera image from displaying.
The risk
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The remedy
Dealers will update the Image Processing Module software, free of charge. Owner notification letters were mailed April 25, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 25S27.

Ford Motor Company · up to 49,399 vehicles across all model years covered

SEAT BELTS

25V093000 · February 14, 2025

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer and Aviator vehicles. The seat belt buckle anchor bolts at one or more seating positions may be improperly secured. Additionally, vehicles may have an improperly secured seat belt retractor anchor bolt and/or seat belt anchor bolt at the second-row center seating position, if equipped.
The risk
A loose seat belt or seat belt buckle may not properly restrain an occupant during a crash, increasing the risk of injury.
The remedy
Dealers will inspect seat belt buckle anchor bolts in all seating positions. Additionally, dealers will inspect the seat belt retractor anchor bolt and seat belt anchor bolt at the second-row center seating position, if equipped. If loose anchor bolts are found, the affected seat components will be replaced. Repairs will be performed free of charge. Owner notification letters were mailed on June 5, 2025. Owners may contact Ford customer service at 866-436-7332. Ford's number for this recall is 25S09.

Ford Motor Company · up to 240,510 vehicles across all model years covered

EQUIPMENT:OTHER:LABELS

24V852000 · November 8, 2024

The defect
Ford Motor Company (Ford) is recalling certain 2020-2025 Explorer, Lincoln Aviator, 2020-2024 Escape, Lincoln Corsair, 2018-2024 F-150, Expedition and Lincoln Navigator vehicles. The air bag warning label may be missing from the dashboard. As such, these vehicles fail to comply with the requirement Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
The risk
Without a label that shows the proper restraint usage guidelines, the occupants may have an increased risk of injury in the event of a crash.
The remedy
Ford will mail owners the warning labels, free of charge. Owner notification letters were mailed December 19, 2024. Owners may call Ford customer service at 1-866-436-7332. Ford's number for this recall is 24C39.

Ford Motor Company · up to 27,678 vehicles across all model years covered

ENGINE AND ENGINE COOLING:ENGINE:HARD PARTS INTERNAL/MECHANICAL

24V635000 · August 23, 2024

The defect
Ford Motor Company (Ford) is recalling certain 2021-2022 Bronco, F-150, Edge, Explorer, Lincoln Nautilus, and Lincoln Aviator vehicles equipped with either a 2.7L or 3.0L Nano EcoBoost engine. The engine intake valves may break while driving, which can result in engine failure and a loss of drive power.
The risk
A loss of drive power increases the risk of a crash.
The remedy
Dealers will perform an engine cycle test and replace the engine as necessary, free of charge. Owner notification letters were mailed July 3, 2025. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S55.

Ford Motor Company · up to 90,736 vehicles across all model years covered

BACK OVER PREVENTION:DISPLAY FUNCTION

24V368000 · May 24, 2024

The defect
Ford Motor Company (Ford) is recalling certain 2020-2024 Lincoln Aviator vehicles. The accessory protocol image module (APIM) can be affected by electromagnetic interference with a cell phone in the vehicle, causing the rearview camera image to flicker or become distorted.
The risk
A flickering or distorted rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The remedy
Owners are advised not to use their cell phones while reversing until the remedy is completed. Dealers will install shielding on the accessory protocol image module (APIM), free of charge. Owner notification letters were mailed on October 23, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 24S35.

Ford Motor Company · up to 109,283 vehicles across all model years covered

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

23V626000 · September 8, 2023

The defect
Ford Motor Company (Ford) is recalling certain 2020-2022 Lincoln Aviator and Ford Explorer vehicles equipped with 3.0L PHEV engines. A manufacturing defect in one or more of the high voltage battery cells may result in an internal short circuit and battery failure.
The risk
Battery failure can cause a loss of drive power, increasing the risk of a crash. Battery failure can also increase the risk of a fire.
The remedy
Dealers will perform a Battery Energy Control Module (BECM) diagnostic test and replace the high voltage battery pack, as necessary, free of charge. Owner notification letters were mailed on April 8, 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford Motor Company's number for this recall is 23S53.

Ford Motor Company · up to 2,954 vehicles across all model years covered

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

23V598000 · August 25, 2023

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator, 2018-2021 Lincoln Navigator, 2022-2023 Ford Transit, and 2021 Ford Bronco vehicles. The rearview camera, or 360-degree view camera if equipped, may not display a rearview image when the vehicle is placed in reverse.
The risk
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The remedy
Dealers will replace the rearview camera, and update the software and wiring as necessary, free of charge. Owner notification letters were mailed November 20, 2023 to Lincoln owners. Ford vehicle owners notification letters were mailed March 4, 2024. Ford remedy parts are anticipated 2nd Quarter 2024. Ford's number for this recall is 23S48.

Ford Motor Company · up to 177,402 vehicles across all model years covered

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

23V342000 · May 12, 2023

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
The risk
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The remedy
Dealers will replace the 360-degree camera, free of charge. Owner notification letters were mailed November 10, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S23. This recall expands and replaces NHTSA recall number 23V-022. Vehicles previously repaired under 23V-022 will need to have the new remedy performed.

Ford Motor Company · up to 442,973 vehicles across all model years covered

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

23V022000 · January 23, 2023

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Explorer, Lincoln Aviator, and 2020-2022 Lincoln Corsair vehicles equipped with a 360-degree camera. The video output may fail, preventing the rearview camera image from displaying.
The risk
Loss of the rearview camera image can reduce the driver's rear visibility, increasing the risk of a crash.
The remedy
Dealers will update the image processing module (IPMB) software, free of charge. Interim owner notification letters informing owners of the safety risk were mailed April 25, 2023. Owner notification letters were mailed February 13, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 23S02. This recall expands and replaces NHTSA recall number 21V-735. Vehicles previously repaired under 21V-735 will need to have the new remedy performed.

Ford Motor Company · up to 382,759 vehicles across all model years covered

SEAT BELTS:FRONT:WARNING LIGHT/DEVICES

22V953000 · December 23, 2022

The defect
Ford Motor Company (Ford) is recalling certain 2020-2023 Lincoln Aviator and 2020-2022 Lincoln Corsair vehicles equipped with a Revel Audio System. When the driver's seat belt is not buckled and the vehicle is started, the seat belt warning system may activate the audible warning chime for an insufficient amount of time of less than 4 seconds. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
The risk
An audible warning chime that does not properly alert of an unbelted seat belt can increase the risk of injury during a crash.
The remedy
Dealers will update the audio control module software, free of charge. Owner notification letters were mailed February 7, 2023. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 22C35.

Ford Motor Company · up to 101,001 vehicles across all model years covered

SUSPENSION:REAR

21V870000 · November 10, 2021

The defect
Ford Motor Company (Ford) is recalling certain 2021 Explorer and Lincoln Aviator vehicles. Incorrect rear suspension module components may have been installed due to a labeling error.
The risk
A rear suspension module with incorrect components may affect vehicle handling, ride height, and braking characteristics, increasing the risk of a crash.
The remedy
Dealers will inspect the rear suspension module, and replace any incorrect parts, as necessary, free of charge. Owner notification letters were mailed December 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S47.

Ford Motor Company · up to 20 vehicles across all model years covered

BACK OVER PREVENTION:SOFTWARE

21V735000 · September 22, 2021

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer, Lincoln Corsair, and Lincoln Aviator vehicles equipped with 360-degree cameras. The video output may fail, preventing the rearview camera image from displaying.
The risk
A rearview camera that does not display an image reduces the driver's rear view, increasing the risk of a crash.
The remedy
Dealers will update the Image Processing Module (IPMB) software, free of charge. Owner notification letters were mailed November 16, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S44.

Ford Motor Company · up to 228,297 vehicles across all model years covered

AIR BAGS:SIDE/WINDOW:CURTAIN

21V652000 · August 23, 2021

The defect
Ford Motor Company (Ford) is recalling certain 2021 Explorer and Lincoln Aviator vehicles. The side air bag attachment weld studs could detach during the deployment of the side air bag, resulting in an improper deployment. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard 214, "Side Impact Protection".
The risk
Improper deployment of a side air bag increases the risk of injury during a crash.
The remedy
Dealers will replace the side air bag assemblies, free of charge. Owner notification letters were mailed September 10, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C19.

Ford Motor Company · up to 592 vehicles across all model years covered

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:COMPRESSOR

21V534000 · July 15, 2021

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Lincoln Aviator vehicles equipped with 3.0L gasoline engines. The wire harness may not be secured properly, possibly contacting the air conditioning (A/C) compressor pulley, and resulting in damage to electrical wires, or the A/C compressor drive belt.
The risk
Damaged electrical wires may short-circuit, increasing the risk of a fire.
The remedy
Dealers will inspect the harness and A/C compressor belt for damage, replacing them as necessary, and install a tie strap to secure the wire harness, free of charge. Owner notification letters were mailed on July 30, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21S34.

Ford Motor Company · up to 33,298 vehicles across all model years covered

BACK OVER PREVENTION:DISPLAY FUNCTION

21V223000 · March 30, 2021

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Lincoln Aviator vehicles. The image processing module may be unable to provide video feed to the display, which could result in a loss of the backup camera image. As such, these vehicles fail to comply with the requirements of the Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
The risk
A backup camera that displays a blank or distorted image reduces the driver's rear view, increasing the risk of a crash.
The remedy
Ford will notify owners, and dealers will update the image processing module software with the latest level, free of charge. Owner notification letters were mailed May 21, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 21C09.

Ford Motor Company · up to 34,952 vehicles across all model years covered

ENGINE

20V788000 · December 17, 2020

The defect
Ford Motor Company (Ford) is recalling certain 2020-2021 Explorer and Lincoln Aviator vehicles. The right hand motor mount fasteners may have been incorrectly tightened, and may loosen over time.
The risk
With a loose motor mount, motor vibration may cause the axle to disconnect from the engine and could result in loss of power, increasing the risk of a crash.
The remedy
Ford will notify owners, and dealers will remove and replace the right hand motor mount fasteners, free of charge. The recall began February 3, 2021. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S72.

Ford Motor Company · up to 1,405 vehicles across all model years covered

STEERING

20V726000 · November 20, 2020

The defect
Ford Motor Company (Ford) is recalling certain 2021 Lincoln Aviator vehicles. The steering knuckles may have been manufactured improperly.
The risk
The improperly manufactured knuckle may fracture, reducing steering control, increasing the risk of a crash.
The remedy
Ford will notify owners, and dealers will inspect the front knuckle, and replace it if necessary, free of charge. The recall began December 16, 2020. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 20S69.

Ford Motor Company · up to 690 vehicles across all model years covered

Defect investigations (1)

An investigation means NHTSA has decided a pattern is worth examining. A preliminary evaluation is often closed with no action; an engineering analysis is the stage that usually precedes a recall.

Loss of Motive Power

EA23002

Closed engineering analysis · opened September 29, 2023 · closed October 31, 2024 · led to recall 24V635

the engine

On July 22, 2022, the Office of Defects Investigation (ODI) granted a Defect Petition (DP22001) and opened a Preliminary Evaluation (PE22007) to investigate allegations of loss of motive power in model year (MY) 2021 Ford Bronco vehicles equipped with 2.7L EcoBoost engines. Complainants were reporting sudden engine failure while driving resulting in a loss of motive power, often without the ability to restart. During PE22007, the cause of engine failure and loss of motive power in the subject vehicles was determined to be intake valve fracture, and the full scope of vehicles affected by the subject defect was identified as all MY 2021-2022 Ford and Lincoln models equipped with either the 2.7L or 3.0L EcoBoost engines, referred to as the “Nano” engine family.  If an intake valve fractures in the subject engines, it may drop into the cylinder and contact the piston, often resulting in catastrophic engine damage. On September 29, 2023, PE22007 was upgraded to an Engineering Analysis (EA23002) to further investigate the subject defect across the full scope of affected vehicles. During EA23002, ODI visited Ford facilities to review technical information related to intake valve fracture in “Nano” engines, coordinated with NHTSA’s Vehicle Research and Testing Center (VRTC), and analyzed updated field data relating the subject defect. Forensic analysis of fractured intake valves demonstrated that the defective components exhibited “grinding burn” or out of specification hardness in the area of the keeper grooves. The presence of grinding burn is evidence that during the groove grinding phase of production, the temperature of the valve became sufficiently high to alter the microstructure of the material and is indicative that the valve supplier’s manufacturing processes were not within control specifications. Grinding burn results in a hard, brittle microstructure and high residual stresses toward the surface of the valve. Through normal engine loading, a valve with grinding burn will likely fracture at the area of highest vulnerability, which is the third keeper groove. In its response to the EA23002 Information Request (IR) letter, Ford provided evidence of 396 customer complaints (including field reports), 825 warranty claims, and 936 engine exchanges. When considering both ODI and manufacturer failure report data, there have been reports representing 1066 unique vehicles within the subject vehicle population. Analysis of the failure report data demonstrates that vehicles equipped with potentially defective intake valves were built within a production “spike period” of May 2021 – October 2021. The beginning of the spike period corresponds to a ramp up in production at the valve supplier manufacturing facility, and the end of the spike period aligns with the implementation of several mid-production process improvements and the decision to change the metal alloy used to produce intake valves from “Silchrome Lite” to “Silchrome 1”. Ford began investigating the subject defect in July 2021, determined the root cause, and took corrective measures for the new production vehicles. Analysis of the failure report data demonstrates that these corrective actions were successful in eliminating the risk of intake valve fracture for subject vehicles produced after October 2021. However, Ford did not take any field action to address vehicles produced during the spike period, and in the several months following the implementation of the production changes, a significant number of field failures continued to occur. It is Ford’s assessment that not all valves produced during the spike period are defective, and that failures associated with the subject defect occur at low time in service. Analysis of the failure report data demonstrates that the vast majority of failures have occurred before 20,000 miles with over half of all reported failures occurring before 5,000 miles. The rate of reported failures related to the subject defect has steadily decreased since November 2021. ODI coordinated with NHTSA’s National Center for Statistics and Analysis (NCSA) to conduct statistical analysis and predict the number of future failures associated with the subject defect. The results of this analysis, and the trends identified through the failure report data are generally consistent with Ford’s assessment that defective intake valves will likely fail at a low time in service and indicate that the majority of subject vehicles equipped with defective valves have already experienced a failure. On August 23, 2024, Ford submitted recall 24V635 for subject vehicles equipped with “Nano” engines and built within the production spike period identified above (total population 90,736 vehicles). The remedy includes an inspection at a Ford/Lincoln dealership where the lifetime engine cycles of the vehicle will be determined. If a vehicle does not meet a threshold for lifetime engine cycles, the dealership will conduct a high RPM engine cycle accumulation procedure, which aims to identify if the vehicle is equipped with defective intake valves. Any vehicle that fails the accumulation procedure will receive an engine replacement under the recall. In addition to recall 24V635, Ford has stated that it will launch customer satisfaction campaign 24N12, which will provide extended warranty coverage to the subject vehicles through the earlier of 10 years or 150,000 miles. In view of the recall action being taken by Ford, ODI is closing this Engineering Analysis. To review the reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

What owners report

Complaints naming each system. One complaint can name several, so these add up to more than 38.

ELECTRICAL SYSTEM 11 29%
ENGINE 6 16%
UNKNOWN OR OTHER 5 13%
POWER TRAIN 4 11%
STRUCTURE 4 11%
VISIBILITY/WIPER 4 11%
BACK OVER PREVENTION 3 8%
FUEL/PROPULSION SYSTEM 3 8%
SERVICE BRAKES 3 8%
VEHICLE SPEED CONTROL 3 8%
EXTERIOR LIGHTING 2 5%
FORWARD COLLISION AVOIDANCE 2 5%

When the complaints arrived

By the year NHTSA received them, which is not the year the failures happened. They peaked in 2025 at 13.

2022 2025 2026
2022 to 2026, the last of them a part year

In owners' own words

Quoted from NHTSA's complaint file. These are unverified accounts by the people who filed them, not findings of fault.

ELECTRICAL SYSTEM

2 injured

My 2021 Lincoln Aviator PHEV lift gate safety stop does not function properly. It will come closing down extremely hard. This will happen when the button is pressed on the lift gate or the hands free feature is triggered. The lift gate will not safety stop and pop back open as it should unless a significant amount of force is used; this is usually 2 or more people trying with all their strength to stop it from closing on them. I have been hurt by this and so has my child. This is a serious safety issue. I have included screenshots from the video (the system won’t let me send the video) I took replicating the issue with it completely crushing a box at the height of my head.

NHTSA complaint 11683995. Filed by an owner and not verified by NHTSA or by us.

SEATS

fire

My vehicle has heated seats. This week, when I was using the heated seats, I noticed a burning sensation on my left buttocks. I later discovered a burn hole in my seat (bottom left) and a matching burn on the coat I was wearing (bottom left). I am reporting this incident I because I believe there is a defect of the heated sweats in my vehicle that could lead to severe burns to passengers.

NHTSA complaint 11506325. Filed by an owner and not verified by NHTSA or by us.

AIR BAGS

crash · towed

I was completely stopped in traffic a car failed to reduce speed and slammed into the back of my car. My neck whipped forward no air bags deployed.

NHTSA complaint 11737219. Filed by an owner and not verified by NHTSA or by us.

ELECTRICAL SYSTEM

towed · 60,000 miles

The contact owns a 2021 Lincoln Aviator. The contact stated that the vehicle did not start, the vehicle was , the hood was raised, the contact went back to the vehicle to try to start, the vehicle would not turn over with clicking in the engine. the vehicle began to smoke with very thick white smoke, the contact was unable to exit the vehicle of the drivers side front seat. The battery was disconnected and a manual latch was discovered on the drivers side door. The vehicle was towed to the dealer but had not been diagnosed or repaired. The manufacturer was not notified of the issue. The approximate failure mileage was 60,000.

NHTSA complaint 11741858. Filed by an owner and not verified by NHTSA or by us.

VISIBILITY
The contact owns a 2021 Lincoln Aviator. The contact received notification of NHTSA Campaign Number: 26V117000 (Visibility); however, the part to do the recall repair was unavailable. The dealer was contacted, and the contact was informed that parts would be available at the end of June 2026. The manufacturer was not contacted. The contact had not experienced a failure.

NHTSA complaint 11750524. Filed by an owner and not verified by NHTSA or by us.

FUEL SYSTEM, GASOLINE

towed · 67,000 miles

The contact owns a 2021 Lincoln Aviator. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while driving 70-75 MPH, the check engine warning light illuminated, and the vehicle stalled. The vehicle was towed to a friend's residence, where it failed to restart. The dealer was contacted and informed that the vehicle would be repaired at the owner's expense because the recall remedy was unavailable. The contact was informed that a reimbursement claim could be filed with the manufacturer afterwards. The vehicle was not diagnosed or repaired. The contact stated

NHTSA complaint 11750650, quoted in part. Filed by an owner and not verified by NHTSA or by us.

POWER TRAIN

98,000 miles

The contact owns a 2021 Lincoln Aviator. The contact stated that while the vehicle was unoccupied and parked on an incline, the vehicle rolled backwards several feet and then came to a complete stop. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact related the failure to NHTSA Campaign Number: 26V402000 (Power Train); however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was approximately 98,000.

NHTSA complaint 11747408. Filed by an owner and not verified by NHTSA or by us.

UNKNOWN OR OTHER
My vehicle is a hybrid and repeatedly gets high voltage battery warnings when the electric battery shows zero miles when idling. Four times it has shown pull over safely messages and high voltage battery warnings and then it is only in auxiliary mode. By the time a tow truck comes it is able to start again and Ford has been unable to find the issue after 4 visits

NHTSA complaint 11746352. Filed by an owner and not verified by NHTSA or by us.

Compare

Other years of the Lincoln Aviator

Model year Complaints Recalls Deaths
2025 13 14
2023 21 16
2022 44 21
2020 105 30

Other 2021 Lincoln models

Every Lincoln on this site — 84 vehicles, 269 recall campaigns and 2 open investigation s.

If this is your car and a dealer keeps failing to fix it, your state's lemon law may require the manufacturer to replace it or buy it back. What each state asks for , read from the statutes.

Where these numbers come from

A complaint is one owner's account and has not been verified by NHTSA or by us. A vehicle with more complaints is not necessarily worse: models that sold in larger numbers collect more of them. How this is counted.

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