Ford Motor Company is recalling 47,804 vehicles across nine 2025 models due to an issue with the Engine Gas Return valve, which can cause excessive EGR flow into the engine. The affected models include:
- Ford Mustang
- Ford Ranger
- Lincoln Nautilus
- Lincoln Corsair
- Ford Maverick
- Ford Escape
- Ford Explorer
- Ford Bronco
- Ford Bronco Sport
According to the National Highway Traffic Safety Administration (NHTSA), “the poppet head within the Engine Gas Return (EGR) valve may detach and allow excessive EGR flow to the engine.” This could result from “inconsistent laser welding penetration during EGR valve production.”
Affected customers may report symptoms such as “weak acceleration, engine vibration, a no start condition, or a check engine light.” Ford’s Critical Concern Review Group (CCRG) initiated an investigation in July 2025 when it received five warranty claims “of Exhaust Gas Return (EGR) valve poppet heads falling off” from the Ford Supplier Technical Assistance (STA) team. All claims came from cars with fewer than 6,000 miles on the odometer.
Ford then replicated the issue in a test vehicle as it continued to receive warranty claims, with many owners reporting a loss of power. In January this year, “CCRG reviewed the additional claims and worked with STA to review the supplier’s production data from when these newly failed EGR valves were produced to further establish the suspect population. The CCRG also further analyzed the newly received claims, citing loss of motive power.”
The NHTSA states in the report that this issue increases the risk of a crash since the “detached poppet head valve may result in loss of motive power (likely at low speeds of 20 kph or below).” Ford has stated that it is not aware of accidents, injuries, or fires due to the EGR issue.
Usually, affected customers would be asked to take their vehicles to the dealership to solve the matter. However, the NHTSA states in this matter that the “remedy is under development. When the remedy is available, owners will be notified by mail and instructed to take their vehicle to a Ford or Lincoln dealer to have the remedy performed.”
