Ford Recalls Over 4,000 Vehicles for Engine Defect That Could Lead to Fires or Power Loss

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Ford Motor Company has issued a safety recall for more than 4,000 vehicles in the United States, including certain 2024–2025 F-150 trucks, Expeditions, and Lincoln Navigators, due to a potential engine defect that could increase the risk of fire or sudden power loss. The problem stems from a misaligned engine cup plug, which may lead to rapid oil leakage from the engine.

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The issue was first identified following a warranty report involving a dislodged cup plug, which caused complete engine failure. Ford traced the cause to a misalignment in the hydraulic press used to install the cup plug in the cylinder head during assembly. This misalignment, which occurred during maintenance at Ford’s Cleveland Engine Plant in September 2024, resulted in deformation of the plug and a reduction in its ability to retain oil. The error was corrected by early October of the same year.

The recall affects 3,072 F-150 trucks produced between September 12, 2024, and January 30, 2025; 995 Expeditions produced between September 23, 2024, and February 9, 2025; and 96 Lincoln Navigators manufactured from September 24, 2024, to October 16, 2024. All affected vehicles are equipped with a 3.5L GTDI gas engine. Ford estimates that about 10% of the recalled vehicles actually have the defect.

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Customers may notice symptoms such as oil leaks, a burning smell, smoke, engine noises, or a dashboard warning indicating low oil pressure. These signs could precede either engine power loss or a fire if oil comes into contact with hot engine components. While no injuries or accidents have been reported, Ford has received multiple warranty and field reports related to the defect.

Owners will be notified by mail beginning May 26, 2025. Dealers will inspect the affected engine components and install a shorter cup plug if necessary. The service will be provided free of charge. Affected customers who previously paid for similar repairs may be eligible for reimbursement under Ford’s existing recall reimbursement program.

Article by multiple RFHC contributors, based upon information from Ford Motor Company, U.S. National Highway Traffic Safety Administration (NHTSA) Safety Recall Report 25V-198

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