Incident: Ford Bronco SUVs 2021 Engine Valve Failure Investigation

Published Date: 2022-07-27

Postmortem Analysis
Timeline 1. The software failure incident involving the 2021 Ford Bronco SUVs occurred in 2021, as indicated by the article mentioning that all problematic SUVs are 2021 models [130111]. 2. Published on 2022-07-27. 3. The incident likely occurred in 2021.
System 1. 2021 Ford Bronco SUVs equipped with the 2.7-liter EcoBoost V6 engine [130111].
Responsible Organization 1. Ford - Ford Broncos equipped with the 2.7-liter EcoBoost V6 engine experienced catastrophic engine failures due to the valves failing, which was identified as a result of the valve 'keepers' not holding the retainer in place [130111].
Impacted Organization 1. Owners of 2021 Ford Bronco SUVs equipped with the 2.7-liter EcoBoost V6 engine were impacted by the software failure incident [130111].
Software Causes 1. The software causes of the failure incident were related to the valves failing due to the valve 'keepers' not holding the retainer in place, allowing the valve spring to detach from the valve, resulting in interference between the valve and piston, which can cause an engine lockup [130111].
Non-software Causes 1. Catastrophic engine failures due to valves failing, specifically related to the valve 'keepers' not holding the retainer in place [130111].
Impacts 1. Loss of motive power at highway speeds with no restart reported by owners of 2021 Ford Bronco SUVs equipped with the 2.7-liter EcoBoost V6 engine [130111]. 2. Catastrophic engine failures due to valves failing, resulting in engine lockup [130111].
Preventions 1. Implementing thorough testing procedures during the software development phase to detect any potential issues related to the valve 'keepers' not holding the retainer in place [130111]. 2. Conducting regular maintenance checks and inspections on the engine components to identify and address any issues before they lead to catastrophic failures [130111].
Fixes 1. Ford could release a software update to address the issue causing the catastrophic engine failures due to the valves failing in the 2021 Ford Bronco SUVs equipped with the 2.7-liter EcoBoost V6 engine [130111].
References 1. National Highway Traffic Safety Administration (NHTSA) [Article 130111]

Software Taxonomy of Faults

Category Option Rationale
Recurring unknown The article does not mention any specific software failure incident happening again at either the same organization (Ford) or at multiple organizations. Therefore, the information related to the recurrence of the software failure incident is unknown.
Phase (Design/Operation) unknown The article does not mention any software failure incident related to the development phases (design or operation). Therefore, it is unknown whether the reported issue was due to factors introduced during system development, system updates, or procedures to operate or maintain the system (design), or if it was due to factors introduced by the operation or misuse of the system (operation) [130111].
Boundary (Internal/External) within_system The software failure incident reported in Article 130111 regarding the 2021 Ford Bronco SUVs experiencing a loss of motive power at highway speeds with no restart is attributed to an issue within the system. The root cause identified by Ford was related to the valve 'keepers' not holding the retainer in place, leading to catastrophic engine failures due to the valves failing. This internal issue within the engine system resulted in interference between the valve and piston, potentially causing an engine lockup [130111].
Nature (Human/Non-human) non-human_actions (a) The software failure incident in the 2021 Ford Bronco SUVs was not directly attributed to non-human actions. The issue was related to catastrophic engine failures caused by valves failing due to the valve 'keepers' not holding the retainer in place, leading to interference between the valve and piston, ultimately resulting in engine lockup [130111]. This issue was identified as a mechanical failure rather than a software failure caused by non-human actions. (b) The software failure incident in the 2021 Ford Bronco SUVs was not directly attributed to human actions either. The root cause of the problem was identified as a mechanical issue with the valves and valve 'keepers' not holding the retainer in place, leading to engine failures [130111]. There was no indication in the article that human actions directly contributed to the software failure incident.
Dimension (Hardware/Software) unknown (a) The software failure incident in this case is not related to hardware but rather to a catastrophic engine failure due to valves failing, specifically attributed to the valve 'keepers' not holding the retainer in place, allowing the valve spring to detach from the valve, resulting in interference between the valve and piston, which can cause an engine lockup. This issue is not originating from hardware components but rather from the design or manufacturing of the engine components themselves [130111].
Objective (Malicious/Non-malicious) non-malicious The software failure incident reported in Article 130111 is non-malicious. The issue with the 2021 Ford Bronco SUVs is related to catastrophic engine failures caused by valves failing due to the valve 'keepers' not holding the retainer in place, leading to interference between the valve and piston. This issue is attributed to a mechanical fault in the engine components rather than any malicious intent to harm the system [130111].
Intent (Poor/Accidental Decisions) unknown The software failure incident related to the investigation into 2021 Ford Bronco SUVs is not directly attributed to poor or accidental decisions. The issue identified by the National Highway Traffic Safety Administration (NHTSA) and Ford is related to catastrophic engine failures caused by valve failures, specifically the valve 'keepers' not holding the retainer in place, leading to interference between the valve and piston and potentially causing an engine lockup. This issue is more related to a mechanical or design flaw rather than poor or accidental decisions [130111].
Capability (Incompetence/Accidental) unknown The software failure incident related to the Ford Bronco SUVs was not specifically attributed to software issues but rather to catastrophic engine failures caused by valve failures [130111]. Therefore, the incident does not fall under the categories of development incompetence or accidental software failure.
Duration permanent The software failure incident mentioned in Article 130111 is related to a permanent failure. The article describes how the 2021 Ford Bronco SUVs experienced a loss of motive power at highway speeds with no restart due to catastrophic engine failures caused by the valves failing. The root cause was identified as the valve 'keepers' not holding the retainer in place, leading to interference between the valve and piston, ultimately resulting in engine lockup [130111]. This issue is not temporary and requires a permanent fix to prevent further incidents.
Behaviour value (a) crash: The software failure incident in the reported article is not related to a crash of the system. It is specifically mentioned that the issue is related to catastrophic engine failures in some 2021 Ford Bronco SUVs due to valves failing, which can lead to an engine lockup [130111]. (b) omission: The software failure incident is not attributed to the system omitting to perform its intended functions at an instance(s). Instead, the issue is related to engine failures caused by valve failures in the mentioned vehicles [130111]. (c) timing: The software failure incident is not due to the system performing its intended functions correctly but too late or too early. The issue described in the article pertains to engine failures in 2021 Ford Broncos equipped with the 2.7-liter EcoBoost V6 engine [130111]. (d) value: The software failure incident is related to the system performing its intended functions incorrectly. The root cause identified was the valve 'keepers' not holding the retainer in place, leading to engine failures in the affected vehicles [130111]. (e) byzantine: The software failure incident is not characterized by the system behaving erroneously with inconsistent responses and interactions. The issue described in the article is specifically related to engine failures in some 2021 Ford Bronco SUVs due to valve failures [130111]. (f) other: The software failure incident is related to the system behaving in a way not described in the options (a to e). The issue is specifically related to catastrophic engine failures in 2021 Ford Broncos caused by valves failing, leading to potential safety concerns and an investigation by the NHTSA [130111].

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence harm, property, theoretical_consequence The consequence of the software failure incident described in the article is related to potential harm to individuals due to the engine failures in the 2021 Ford Bronco SUVs. The article mentions that the loss of motor power in the vehicles is a result of catastrophic engine failures caused by valve issues, which can lead to engine lockup. This could potentially result in harm to individuals if the engine failure occurs while driving at highway speeds [130111].
Domain transportation (a) The failed system in this incident was related to the transportation industry. The software failure incident involved some 2021 Ford Bronco SUVs equipped with the 2.7-liter EcoBoost V6 engine experiencing a loss of motive power at highway speeds due to catastrophic engine failures caused by valve issues [Article 130111].

Sources

Back to List