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Ford F150 3.5L Ecoboost Rattle Upon Start Up- Timing Chain Stretch Issues TSB

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775K views 1.4K replies 231 participants last post by  snakebitten  
#1 ·
Ok so some may know about this some may not but it is something that is coming on strong with many showings at dealerships across America. So as most know it is timing chains that are prematurely stretching causing this startup noise. The news is that there is updated parts out there to address this and Ford now has a TSB on this issue formally admitting to it being a common problem. I go over it all in this video. There is also a link to just how it sounds in the description of the video on youtube. Hopefully more dealers will be willing to dive into the engine with some guidance from Ford now.
 
#761 ·
My chain has been rattling for the last 4 months. I have dropped off at the dealer twice and it did not make the rattle. After going back and forth, I got the dealership to accept videos as evidence. I have full powertrain warranty, and I'm dropping truck off on Monday. But before FORD will authorize the repair, the dealer is supposed to look at oil filter for shavings, verify crankshaft end play is out of spec, and check the cams for scarring and report back. Sounds like they are trying to get out of doing the repair and I'm getting ready to get the shaft. Has anyone else had to go through this bull**** before fix was "authorized"?
 
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#765 ·
I've always thought the noise came from the tensioner loosing oil prime or pressure after sitting awhile causing the chain to be loose for a moment on start up. The new tensioner looks like it has a ratcheted shaft on it that locks it in place as parts ware. Keeping the chain tight. Is that what that is?
 
#766 ·
It was never the tensioner or then chain making the noise it's the phasers themselves.
 
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#767 ·
Well I just dropped it off this afternoon. Again, I’m afraid I’m getting ready to get the shaft if they check everything they say they are going to and find nothing wrong. I don’t see where the cams would be effected from timing chain stretch. I Will keep you guys posted.
 
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#769 ·
I've just started to get the rattle at 105k. Sounds like a fan blade hitting something for a few seconds on cold start.

Any recommendations on taking it into the dealer, eg. what all should I ask for? I've got premium care so I want to make sure everything that can be replaced will be replaced.

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#770 · (Edited)
Look at page 47 of this thread at the post by rbrown listing timing components he would replace. I asked by dealer for TSB 16-0027 and told them I would provide the additional parts for install. (Oddly the TSB doesn't include things like tensioner and guides etc.) They didn't have a problem with that as long as I provided the parts (or part numbers) and paid the extra hours of labor (which I would estimate at 2 hours). I would also get a water pump while they are in there. They should also be looking at all other components for excessive wear. Also if they perform the TSB, have them change to oil.

From my research **use with caution**
TSB Parts
Actuator
Part Number: AT4Z-6C525-B

Actuator
Part Number: AT4Z-6256-B

Bolt
Part Number: AT4Z-6279-D


Bolt
Part Number: AT4Z-6279-E


Ford Transit-150/250/350 Engine Timing Chain
Part Number: AT4Z-6268-C


Ford Transit-150/250/350 Engine Intake Manifold Gasket
Part Number: AA5Z-9439-A

Valve Cover Gasket
Part Number: BL3Z-6584-A

Valve Cover Gasket
Part Number: BR3Z-6584-B

Seal
Part Number: BL3Z-9E583-B

Gasket
Part Number: BR3Z-8507-C

Ford F-150/Lincoln Mark Lt Engine Water Pump 37.5Mm O-Ring
Part Number: BR3Z-8527-A

Housing Gasket
Part Number: 7T4Z-8590-A

SEAL ASM CRANKSHAFT OIL
Part Number: XW4Z6700AA

Timing Cover Gasket
Part Number: BR3Z-6020-A

Crankshaft Pulley Bolt
Part Number: F5RZ-6A340-B

Sealant - Silicone
Part Number: TA-357-

Remover - Silicone
Part Number: ZC-30-A

Cleaner - Metal Surface
Part Number: ZC-31-B


NON TSB Parts listed by rbrown
2X Control Valve Solenoid
Part Number: AT4Z-6M280-A

2X Control Valve Solenoid
Part Number: AT4Z-6M280-B

2X Secondary Timing Chain
Part Number: AT4Z-6268-A

Primary Ford Expedition/Lincoln Navigator Engine Timing Chain Tensioner
Part Number: BL3Z-6L266-A

2X Secondary Tensioner
Part Number: AT4Z-6K254-A

Tensioner Arm
Part Number: AT4Z-6B274-A

Tensioner Arm
Part Number: AT4Z-6K255-A

Chain Guide
Part Number: BL3Z-6K297-A

Chain Guide
Part Number: AT4Z-6K297-B

2X Secondary Chain Guide
Part Number: AT4Z-6K297-D
 
#776 ·
How are you able to control how long it does it for? Or are you just advising it only did it briefly? Have any secret squirrel information to limit the rattle duration?


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#780 ·
So Ford is self-inflicting more trouble for them and the customer. Crazy.

Supply-chaining is far more complicated than the consumer might realize.
We simply assume the OEM would know what they're doing.

Nice service offer Ryan.
 
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#782 ·
Well, it happened to me. 2012 3.5. P0016 codes all over the place. Ford said it is a stretched chain. They didn't know about the need to replace the phasers. I had to ask for that. $3,500. I've got to ask what tsb they are working from to see their parts list.
After it's fixed, should I sell the truck? It's only got 75,000 miles.

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#783 ·
It took 75,000 miles for this problem to present itself. I'd say, if it is fixed properly, then there shouldn't be any need to sell it and you could get a lot more miles out of it. ;)
 
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#785 ·
Contact rbrown. Or read this whole thread the tsb has been posted numerous times.
 
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#786 ·
Ford days tsb 17-0026:
Tech(s):
BL3Z*6D256*B 1 TENSIONER
BR3Z*6584*B 1 GASKET
DL3Z*6584*C 1 GASKET
BL3Z*9417*A 1 GASKET
FL*500*S 1 FILTER ASY - OIL
*W503297*S900 1 BOLT
*W520100*S437 1 NUT - HEX.
TA*357* 1 SEALANT - SILICONE
ZC*30*A 1 REMOVER - SILICONE
ZC*31*B 1 CLEANER - METAL
SURFACE
VC*3*B 1 ANTI-FREEZE
XO*5W30*DSP 6 OIL - ENGINE 22.50
AT4Z*6256*B 2 SPR Rply STOP to OptOut.

Did anyone know if this includes the VTCs, or VCTs? I'm still trying to get a handle on the terminology.

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#788 · (Edited)
Be careful. There are multiple TSBs out for similar issues. The one you referenced (17-0026) does not include phasers (Exhaust and Intake VCT) but is only a tensioner kit (which I assume is the tensioner and tensioner arm and chain (because it is not listed as a separate part)).

Important, does your or did your vehicle rattle for 1-4 seconds at startup after a cold-soak? If so, you probably want TSB 16-0027 plus a bunch of other parts listed by rbrown on page 44 (I think) and in post #779. If no rattle, ford is only inclined to put the minimum number of parts in to make your problem go away and will probably follow 17-0026.
 
#791 ·
I asked them if they planned on replacing the phasers and they said"no". I told them to, which added almost $1,000 to the bill. My concern is that the sensors, and solenoids won't get replaced. From pics I've seen, it looks like solenoids are internal, and I'll lose my chance. But the sensors are on a wiring loom external to the engine, and can be replaced by me later.
Since the truck is out of waranty, they'll do whatever I pay for. I just don't went this to cost $5,000.

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#792 ·
So do the work yourself. Should cost $1500
 
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#794 ·
Ryan, posting Gen2 eye-candy in this thread is a heartbreaker, unless you point out that you have even BETTER Gen1 pieces coming down the pipe. ;)

It's true. Mosey on over to his never-ending-build-thread. Ryan describes an upcoming Gen1 timing chain solution.
I realize it's not much consoling for anyone who needs it yesterday, but if you can nurse that baby along for just a few weeks more......

I'm a happy Gen2'er and very pleased at the things Ford addressed. But I also know that eventually the Gen2 weaknesses WILL be revealed. It just takes miles\time.

So I don't gloat! (much)
 
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#798 ·
Guys I am pretty sure I heard the dreaded sound this morning upon cold start up! It didn't do it again after that I called dealership and they of course played it off. I have 79k on my 2013 F150. I do have Stated Policy with Easy-care and timing chain is a covered part but I wonder if it actually has to fail first? Does anyone have experience with an extended warranty and this particular issue?
 
#799 ·
Keep pushing them, if not, take it elsewhere!. I had to drive around back and forth till the light came on. It will be fine for a while. But don’t stop complaining about it. Take it all the way to ford complaint dept. Good thing you have insurance on it.


2012 screw 3.5L
 
#800 ·
These horrible aluminum tensioners they send people are a problem. They are not working well, they are week IMO, and I will not and cannot use them. So take what I say with a grain of salt but look for yourself. Geomoetry is very close on primary chain, so the aluminum tensioner I installed this morning, I’ve removed several times, it has broken once, and it moved out .500” so far spinning the timed motor over 75 times

Yes. \/

Image


No (full disclosure, all my customers run image one tensioner, not the one below. All of them are smiling ear to ear with zero issues.

No. \/

Image
Image



And here is a raptor with 9600 miles on it. Why doesn’t this use up almost all the teeth to tension? Hummmmm?
Image
 
#802 ·
I have a 2011 f 150 that has been in the shop 3 times 3weeks at the time and can tell you this truck was pushed on me as being better than the v8 , nothing but problems . the twitter for ford guy i tweeted and @FTC was @kenatcman. Any one having this problem or attorney interested should get a class action lawsuit started. 2009-2011 vehicles are having this problem with v6 twin turbo
 
#805 ·
My recommendation is that dual variable overhead cam engines should be worked on by qualified persons. It is not cut and dry, and it is not just lining timing marks. Trust me, I get many calls.

Not saying don’t do the work yourself, but make sure you can take this job on and worse afford the new motor should it be wrong.

There are changes right now to primary tensioner and some parts. From our testing and development the newest tensioner and some components that are the new updated parts are not the best ones to use.
 
#810 ·
I'm only to page 46 yet, but it appears some last 60k+ miles after they first hear it, and some went 200 miles between first noise and failure. My engine had intermittent phaser noise on startup when i bought it, and worked fine for over 12k miles, but now I believe I'm busted.
 
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#815 ·
The timing phaser clacking and a stretched chain are generally two different things and should not be treated as one.

1-When the variable cam timing in degrees intake bank1 rolls aft (positive) +6 degrees you will throw a check engine light indicating a stretched chain.

2-I am not saying not the have the phaser clacking issue addressed but if you are able to watch your
variable cam timing as mentioned you ***can*** generally know where you stand.

3-Oil analysis will be important in my opinion to monitor wear. The phasers clacking on cold start is a result of phaser bleeding down or draining back which it is not suppose to do.

4- If you want to help your situation regarding the cold start noise. (let’s say you don’t have the money and are in a tight spot) and you literally cannot fix the truck do to those type of circumstances)
Put your foot to the floor turn the key until the oil pressure builds then let off the peddle and start the truck. Oil pressure will build filling what has drained back or bled down. It isn’t a permanent fix and should not be treated as such. However it will prevent that cold start clacking noise which will prevent accelerated wear in the phasers. It will do nothing with any accelerated stretching of the chain.

If you do notice your variable cam timing intake bank 1 rolling to + 6 degrees or more, you should have it fixed because letting it go, it will eventually stretch past what is acceptable and you will bend a valve or have other issues.
 
#898 ·
Point #3 is interesting to me. I get a < 1 sec rattle generally on mornings, but a much more significant rattle (2-3 sec) occurred last week after I changed the oil. It didn't even sit overnight, it was just ran a few hours after draining and refilling the oil. A week later, it is back to normal, no rattle or just under a second.
 
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