Ford is recalling 10,001 vehicles equipped with 2.3L and 1.5L engines after discovering an issue with their pistons. The automaker identified 38 engine failures at its manufacturing plants during end-of-line (EOL) testing.Affected Ford models include the 2026 Explorer, Mustang, Ranger, Bronco, and Bronco Sport. According to a National Highway Traffic Safety Administration (NHTSA) recall report, the "affected vehicles' engines may experience failed piston domes resulting from a crater crack at the pistons' Nickle-resistant (Ni-Ring) insert and aluminum interface."Failure of a piston dome can lead to the loss of motive power, thereby increasing the risk of a crash. The source of the problem was traced back to a loose lock nut on the piston supplier's machining tool. This caused the tool to " intermittently impact the Ni-Ring insert and fracture the intermetallic bond."AdvertisementAdvertisementOwners whose vehicles are included in the recall population have been asked to look out for "a Check Engine Light (CEL), engine noise, or misfire," the report added. Ford began investigating the issue in March 2026 after an Explorer and five Bronco Sport vehicles suffered engine failures during end-of-line testing. Teardowns found failed piston domes, with further analysis tracing the problem to a bond failure between the piston's Ni-Ring insert and aluminum material.The piston supplier determined that a machining collision could intermittently create cracks at the Ni-Ring-to-aluminum interface. Between January 26 and March 6, 2026, an ultrasonic tester also failed to detect the cracks because its sensor had been replaced without updating the device parameters. Ford subsequently conducted additional testing to understand how the defect could progress to engine failure.By August 12, Ford had identified 38 engine failures at its plants, involving 16 1.5-liter and 22 2.3-liter engines, along with 13 potentially related failures in the field. Following a review on August 18, Ford approved a field action, although the automaker said it was unaware of any accidents or injuries linked to the issue.Ford's Remedy ProgramOwners of the vehicles included in the recall population will be notified by mail, instructing them to take their vehicles to a Ford or Lincoln dealer, where the engine will be inspected for cracked pistons. Vehicles that do not pass the inspection will have their engine long block replaced. This service will be performed at no charge.AdvertisementAdvertisementFord notified dealers on August 28, 2026, with interim owner letters scheduled to be mailed between September 4 and 11. Remedy notification letters are expected to follow between December 21 and 31, while affected VINs became searchable on August 28.