NHTSA Complaint #11575053 — 2019 FORD RANGER

2019 Ford Rangers were shipped without an engine cover to protect the engine from water intrusion.  This, along with the design of the plastic cowl at the base of the windshield being a 2 piece design with a seam directly over the engine bay, allows water to drain into the engine bay during periods of heavy rain. Water will drain from the windshield into the top of the engine, and begin filling the spark plug wells under the ignition coil boots and into the engine head.  This water intrusion can cause engine misfire codes as well as a loss of power while driving, and on multiple instances while merging into traffic, the engine would bog down.  It wasn't until the most recent occurrence that a check engine light came on.  I immediately pulled into a shop and they found the plug wells were rusted, corroded and full of water from this happening since the day it rolled off the lot in 2019.  I have had an independent mechanic assess the damage as well as had the vehicle towed to a local Ford dealer and they found the same condition- with the only solution to replace the engine head as they are unable to remove the plugs due to the damage caused by the water intrusion. An owner should not have to be concerned with parking or driving a vehicle in the rain and whether it will suddenly lose power while driving at highway speeds.  This is a safety issue that Ford should be forced to take care of.  They are aware of the issue and have been as they have issued multiple service bulletins with a solution for misfires to change plugs and install an engine cover.  An engine cover has no bearing on an engine misfire but it shows Ford knows water is getting into engines and causing these problems. Engine/plugs/coils failed, it is available for inspection. Mine and public safety was at risk when driving as it lost power merging into traffic.   Problem has been confirmed by dealer and independent mechanic.   Last instance (2/9/24) was first time a CEL came on while driving