22E051 – Stuck EGR Valve May Cause Loss of Drive Power – BorgWarner

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-051
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
BorgWarner JUN 27, 2022 NHTSA Recall No. : 22E-051 Manufacturer Recall No. : 22V-284 Manufacturer Information :
Manufacturer Name : BorgWarner
Address : 3800 Automation Ave.
Auburn Hills MI 48326 Company phone : 8647109450
Population :
Number of potentially involved : 2,217 Estimated percentage with defect : 100 %
Equipment Information : Brand / Trade 1 :
Model : BorgWarner EGR Valve Part No. : LX6E 9D475 AB Size : 20 mm Function : exhaust gas rec
Descriptive Information : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were set to incorrect force specifications from May 2021 to August 2021 for Ford-purchased products and from June 2021 to August 2021 for Stellantis-purchased products. BorgWarner has since corrected its manufacturing processes by setting its machines to the correct force specifications, which has eliminated the potential defect. The recall population was determined by traceability of the valves involved in the manufacturing process when the machines were not properly set. EGR Valve Assembly (for use in FCA vehicles) 2021-2022 1308 (note: subject to FCA’s recall)
EGR Valve Assembly (for use in Ford vehicles) 2021-2022 909 Production Dates : MAY 01, 2021 – AUG 31, 2021 Part 573 Safety Recall Report 22E-051 Page 2 Brand / Trade 2 :
Model : BorgWarner EGR Valve Part No. : 05281255AK Size : 20 mm Function : Exhaust Gas rec
Descriptive Information : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were set to incorrect force specifications from May 2021 to August 2021 for Ford-purchased products and from June 2021 to August 2021 for Stellantis-purchased products. BorgWarner has since corrected its manufacturing processes by setting its machines to the correct force specifications, which has eliminated the potential defect. The recall population was determined by traceability of the valves involved in the manufacturing process when the machines were not properly set.
Production Dates : MAY 01, 2021 – AUG 31, 2021 Description of Defect :
Description of the Defect : A washer inside the EGR valve may become loose while the vehicle is operating.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : The consequence of the potential defect is that the EGR valve may become
stuck in position, which may cause an unexpected loss of motive power during low load conditions.
Description of the Cause : A staking force may cause a washer in the EGR valve to become loose. Identification of Any Warning
that can Occur : The “check engine” light in FCA’s and Ford’s vehicles should illuminate if the valve becomes stuck in place. The driver may also experience drivability issues. Involved Components : Component Name : EGR Valve
Component Description : 20 mm Exhaust Gas Recirculation Valve Component Part Number : LX6E 9D475 AB, 05281255AK Supplier Identification : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-051 Page 3 Component Manufacturer
Name : BorgWarner Turbo & Emissions System Address : NR
Foreign States
Country : Mexico Chronology :
On September 7, 2021 Ford notified BorgWarner of an EGR valve that failed at vehicle assembly plant for setting a check engine light
On September 9, 2021 BorgWarner provided Ford with a list of suspect valve serial numbers that were produced with an incorrect force setting
On August 10, 2021 Stellantis notified BorgWarner of an EGR valve that failed at vehicle assembly plant for setting a check engine light
On August 14, 2021 BorgWarner provided Stellantis with a list of suspect valve serial numbers that were produced with an incorrect force setting
On August 27, 2021 BorgWarner provided Stellantis with an expanded list of suspect valve serial numbers based on root cause testing so that Stellantis could determine how this issue impacted the vehicle performance On September 10, 2021 the Ford vehicle plant team made the assessment that it was unnecessary to try to contain the issue at its facility
On June 15, 2022 the product engineering team at Ford’s headquarters made an assessment that the Ford application is not affected by a “loss of motive power” in the same way that the Stellantis application is affected. Description of Remedy :
Description of Remedy Program : Ford reviewed the issue internally and determined that it was not safety
related. FCA is separately conducting a recall to replace all of the EGR valves at issue in FCA’s vehicles. See Recall 22V-284. BorgWarner understands that FCA intends to file the required quarterly reports as part of its recall campaign. How Remedy Component Differs from Recalled Component : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were calibrated to incorrect specifications. BorgWarner has since corrected its manufacturing processes by calibrating its machines to the correct specifications, which has eliminated the potential defect. Specifically, the washers in the valves produced using the corrected manufacturing processes do not come loose due to a staking force when operating within Ford’s and FCA’s vehicles. The valves produced using the corrected manufacturing processes cannot be distinguished based on their external characteristics. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-051
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The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
BorgWarner corrected the manufacturing processes that resulted in the potential defect as of August 14, 2021 for the valves used in FCA’s vehicles and September 9, 2021 for the valves used in Ford’s vehicles. BorgWarner effected the correction by setting its machines to the correct specifications. Recall Schedule :
Description of Recall Schedule : FCA has already commenced its own recall campaign with respect to the
valves used in FCA’s vehicles (Recall 22V-284 (filed by Chrysler (FCA US, LLC)), and BorgWarner has already notified Ford of this potential defect with respect to the valves used in Ford’s vehicles, and Ford has conducted its own assessment regarding this matter.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-051
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
BorgWarner JUN 20, 2022 NHTSA Recall No. : 22E-051 Manufacturer Recall No. : 22V-284 Manufacturer Information :
Manufacturer Name : BorgWarner
Address : 3800 Automation Ave.
Auburn Hills MI 48326 Company phone : 8647109450
Population :
Number of potentially involved : 2,217 Estimated percentage with defect : 100 %
Equipment Information : Brand / Trade 1 :
Model : BorgWarner EGR Valve Part No. : LX6E 9D475 AB Size : 20 mm Function : exhaust gas rec
Descriptive Information : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were set to incorrect force specifications from May 2021 to August 2021 for Ford-purchased products and from June 2021 to August 2021 for Stellantis-purchased products. BorgWarner has since corrected its manufacturing processes by setting its machines to the correct force specifications, which has eliminated the potential defect. The recall population was determined by traceability of the valves involved in the manufacturing process when the machines were not properly set. EGR Valve Assembly (for use in FCA vehicles) 2021-2022 1308 (note: subject to FCA’s recall)
EGR Valve Assembly (for use in Ford vehicles) 2021-2022 909 Production Dates : MAY 01, 2021 – AUG 31, 2021 Part 573 Safety Recall Report 22E-051 Page 2 Brand / Trade 2 :
Model : BorgWarner EGR Valve Part No. : 05281255AK Size : 20 mm Function : Exhaust Gas rec
Descriptive Information : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were set to incorrect force specifications from May 2021 to August 2021 for Ford-purchased products and from June 2021 to August 2021 for Stellantis-purchased products. BorgWarner has since corrected its manufacturing processes by setting its machines to the correct force specifications, which has eliminated the potential defect. The recall population was determined by traceability of the valves involved in the manufacturing process when the machines were not properly set.
Production Dates : MAY 01, 2021 – AUG 31, 2021 Description of Defect :
Description of the Defect : A washer inside the EGR valve may become loose while the vehicle is operating.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : The consequence of the potential defect is that the EGR valve may become
stuck in position, which may cause an unexpected loss of motive power during low load conditions.
Description of the Cause : A staking force may cause a washer in the EGR valve to become loose. Identification of Any Warning
that can Occur : The “check engine” light in FCA’s and Ford’s vehicles should illuminate if the valve becomes stuck in place. The driver may also experience drivability issues. Involved Components : Component Name : EGR Valve
Component Description : 20 mm Exhaust Gas Recirculation Valve Component Part Number : LX6E 9D475 AB, 05281255AK Supplier Identification : The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-051 Page 3 Component Manufacturer
Name : BorgWarner Turbo & Emissions System Address : NR
Foreign States
Country : Mexico Chronology :
On September 7, 2021 Ford notified BorgWarner of an EGR valve that failed at vehicle assembly plant for setting a check engine light
On September 9, 2021 BorgWarner provided Ford with a list of suspect valve serial numbers that were produced with an incorrect force setting
On August 10, 2021 Stellantis notified BorgWarner of an EGR valve that failed at vehicle assembly plant for setting a check engine light
On August 14, 2021 BorgWarner provided Stellantis with a list of suspect valve serial numbers that were produced with an incorrect force setting
On August 27, 2021 BorgWarner provided Stellantis with an expanded list of suspect valve serial numbers based on root cause testing so that Stellantis could determine how this issue impacted the vehicle performance On September 10, 2021 the Ford vehicle plant team made the assessment that it was unnecessary to try to contain the issue at its facility
On June 15, 2022 the product engineering team at Ford’s headquarters made an assessment that the Ford application is not affected by a “loss of motive power” in the same way that the Stellantis application is affected. Description of Remedy :
Description of Remedy Program : Ford reviewed the issue internally and determined that it was not safety
related. FCA is separately conducting a recall to replace all of the EGR valves at issue in FCA’s vehicles. See Recall 22V-284. How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production : The potential defect resulted from manufacturing processes in which BorgWarner’s machines were calibrated to incorrect specifications. BorgWarner has since corrected its manufacturing processes by calibrating its machines to the correct specifications, which has eliminated the potential defect. Specifically, the washers in the valves produced using the corrected manufacturing processes do not come loose due to a staking force when operating within Ford’s and FCA’s vehicles. The valves produced using the corrected manufacturing processes cannot be distinguished based on their external characteristics.
BorgWarner corrected the manufacturing processes that resulted in the potential defect as of August 14, 2021 for the valves used in FCA’s vehicles and September 9, 2021 for the valves used in Ford’s vehicles. BorgWarner effected the correction by setting its machines to the correct specifications. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 22E-051
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
Recall Schedule :
Description of Recall Schedule : FCA has already commenced its own recall campaign with respect to the
valves used in FCA’s vehicles (Recall 22V-284 (filed by Chrysler (FCA US, LLC)), and BorgWarner has already notified Ford of this potential defect with respect to the valves used in Ford’s vehicles, and Ford has conducted its own assessment regarding this matter.
Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR Address : NR
NR Country : NR Company Phone : NR
* NR – Not Reported

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