sorry to hear you're part of the club. def take it in to document your problem before the emissions warranty is up at 80k. there have been a number of "we can't reproduce" responses from dealerships if it's only intermittent. that way if they can't reproduce now, you're on record that you've brought it in before warranty is up. you'd have a fight on your hands probably but you'd be in the right so to speak.

 

I will say that around town my truck is fine. But today I put it in the shop because of the Rattle and a misfire upon acceleration. They said it was a timing issue causing all my problems it's sixty nine thousand miles. I still have one more year left on my warranty. Warranty will cover it. It devastates me that my truck is down and hurt but knowing that the problem will be fixed makes me feel better. Mine is a 2011 fx2

 

The dealership mechanic drove the truck and definetly felt the issues. So i still have a little faith in dealerships...plan on a tuner as soon as warranty is over.

 

Update. Service department called. Mechanic says the engine needs to be rebuilt. Damage to timing chain area. Sats something came loose and that it was a major fix. I bought extended warranty so im ok with it as long as its done right. Now waiting on warranty company to approve repair.

 

I just joined this forum to reply to this thread. Here's my story, in hoping it may help others, and also help me with my next issue. The second issue to be cross-posted in correct place - I will edit and reference new post when I get it up.
I have a 2013 F150 FX4 Supercrew 3.5L ecoboost. A few extras, but I've kept this truck mainly stock.
History:
-Purchased 3/13
-5/13 a semi blew a tire on the interstate, in retrospect, the tire would have been a better choice to hit than the exit sign I took out. Hood, grille, bumper, headlight, fender, etc (tune of $12k), no frame damage
-early '15, about 28k, started noticing 2-5 second rattle on start.
-mid '15, noticed slow acceleration, misfire at idle (rough)
-at 34k took into dealer, dealer replaced plugs, wires, coil from a TSB. could not replicate startup. indicated rattle was from vacuum pumps and/or turbo spool. which i knew was not the case.
-intermittently continued, 1 -2 times a week average.
-at 43k, a few weeks ago, it started happening almost every start.
-I did a week of research. Videos. Printed copies of TSB for existing timing chain issue. Scheduled with my dealer & dropped off everything. TSB handed to them, one in the front seat, and a copy taped to the under side of the hood.
-The next morning they called, said thats what it was, said it would be covered under warranty. Recommended I did not drive until corrected.
-a couple days turned into a couple more, 12 days later I had my truck back. Parts took forever to come in. I stopped by a few times, engine out, disassembled, cleaned, ready to go. Actual chain & cams took the longest.
-Replaced 4 VCT's, chain, water pump, cams, sprocket, idler pulley, belt, new oil, new coolant, flushed trans, gaskets, etc.
-I had purchased an Easy Care package which is refunded if not used at the time i bought the truck, which thankfully covered rental (only 5 days). The dealer picked up the other 7 days.

My advice for taking it in would be to present video/audio evidence (this seemed to stop the "oh we couldnt recreate it" issue) as well as knowledge of the issue and a copy of the TSB.

My problem now is that I have had the truck back a few days and there's a definite tick to the engine. I know, DFI, high pressure valves, some valve lash sound is normal. The problem is I'm not sure how normal. Or if theres any kind of stretch or "learn" period for the VCT's. Audio clip attached (it made me zip it to be able to attach it for some reason)

View attachment idle under hood.zip

On the plus side - no rattle on startup!

 

Yikes, that is not the normal HPFP ticking these things have.

 

Glad you got the timing chain done, but I agree with above statement. Ain't normal. Go back to dealer.

 

Well talked to the dealer a few times since Thursday. When they started the truck on Friday they heard no rattle. Kept it over the weekend and started it Monday morning. No rattle. Then they called yesterday afternoon and said they did hear something when they started to move it and wanted to keep it one more day. Today they called and said they started it this morning first thing and heard nothing. I am at the point where I need to go back to my purchasing dealer and see what they can do. I also plan on videoing my start-ups from now on.

 

Hope all goes well. Seems to me Id want a diff mechanic working on it...

 

Hey guys im new to this forum but I'm having similar issues with my ecoboost. I just hit 93k on a 2011. I'm getting rattling at cold start, and the same rattling noise when transmission shifts under stress like steep grades. I've always changed oil with full syn at 3-4K consistently. I'm also getting an excessive amount of soot coming from the exhaust. I haven't made an appointment with ford yet but I do plan on it very soon. The truck was great never had a problem up until a few weeks ago. I'm hoping you guys have some insight on this because I can't stand dealerships. I did purchase an extended warranty through warranty soloutions but I don't know what's the dealership is going to try and con me into

 

Your answers lie in this thread. If you've got extended warranty, then there should be no issue, and yes, go to dealership.

 

I took it in yesterday morning. Picked it up tonight. Ran like a top. They attributed it to a plug wire routed incorrectly - was arcing out. I made it about 15 miles, stopped, heard it instantly. Same exact sound. Called the service manager. Round 3 tomorrow.

 

Well here is my latest. After getting my truck back from the local dealer on Tuesday I have heard the noise the last 2 mornings when I started the engine. I did video record my engine at start up and plan to from now on. I called my purchasing dealer yesterday to see what they can do. They were going to check and let me know. Today I heard back and they say since I am out of warranty there is nothing they can do. They said I have to contact Ford customer service to go further and gave me the phone number.
I am sorry but I do not think this is right. I understand my extended warranty is just past but this seems to be a prevalent issue with the earlier 3.5 engines. I paid over one thousand dollars to upgrade to this engine after seeing and hearing advertisements about its benefits and durability. Now, when it has a problem by no fault of mine, I am told that it will not be taken care of. This was my first Ford and may be my last. I have contacted Meagan on here to see if she can assist me.

 

Your out of both standard and extended warranty. Ford's obligations to you are over. It's not safety related therefor it will never be a recall.

I know it sucks and don't blame you for hating on ford for it.

Too bad someone hasn't come out with a vct delete like the 5.4s had.

 

I'm only at 43k, so still under powertrain. they came and got it this morning & left me a new MKZ. best rental I've had so far. The foreman said it was fine to drive, I disagreed as did the manager, so theyre tearing the engine back down. I'm leaving on a road trip though, so changed that for an Expedition tonight (loaner/rental #5). So they have 10 days to find it. damn thing sounds like its going to throw a rod.
they replaced the cams, sprockets, and everything on the belt.. I will say - dealer has been great. Granted I am a difficult customer and pulled some strings with the owner (what few strings I have) so that helps I'm sure.
I have the same puzzled feeling about this entire thing. I watched the whole Mike Rowe ecoboost promo I'm sure most did. Nearly melt it, freeze it, put 250k simulated miles on it, then run the baja. Drove it and compare to the V8 it wasnt even a contest. Incredible torque. I still miss the sound of 40 series flows on the chevy's ive owned... but hearing those turbos spool up is a close second.
If i had it to do over. i would have gotten a superduty or an impractically amazing raptor.
10 days til update

 

I dont have a FORD extended warranty. I have Louisiana dealership service warranty. Its covered till 100k on mine.

 

I have had this problem for a few weeks now.. only happened a few times. I took it to Ford dealer as I have 52K and over a year on my 2011 model powertrain.
The first day they could not reproduce the sound. but hey called me this morning and the truck made the noise... it was chilly last night.. not sure why that seems to matter ,but I'm reading that a lot.
The are going to see if they have all of the parts on hand and start to fix it... I am relieved that this will get done.

 

Make sure that they are aware of replacing the cam phasers. Some dealerships have only tried to replace the chain. But the correct, latest & greatest, fix from Ford is the chain and phasers.

 

You MOST definitely need new phasers and new chains. I am not sure the "new" phasers from 16+ trucks fix the problem though. I did read where this rattle existed on a 16 already.

 

My truck started to do this recently. I have 46xxx miles. I recorded it on my phone. I called my service guy on Thursday and he said it sounded like the timing chain or vacuum issue. He told me to bring it in, show me the video, and they would take care of it. Of course they want to try and replicate it but based on my conversation and reading the tsb, it shouldn't be a problem getting it fixed. I'll let you all know how it goes. It's funny how some service centers are more accommodating then others. I hope this ends well and wish others the best of luck. This is my third tsb in just under 2 years. Ford has always taken care of me. I'm crossing my fingers on this one. When we use are trucks as trucks, we have to expect some maintenance. I feel bad for those that are past their warranty, we spend a lot of money on these things and expect them to last. The problem is they are machines and machines will fail at some point. Best of luck to all going through their issues.

 

Just got a call from Ford. They ordered the parts to fix the timing chain. I will post the TSB number if it is different then the one I provided them, 16-0027.

 

Ok, new development. Mechanic says its actually a turbo failure and they will replace the turbo and manifold. Warranty thank God.
I told him to install and drive it like he stole it cause if it screws up its not leaving the dealership!

 

Guess what...Our Lovely dealership mechanics thought they fixed my turbo and it was to fix rattle...well maybe...NOW after parts replaced, I requested that they drive it hard up and down the service road to check and see if its functioning right...well there is a miss in #2, they replaced plug and coil pack, still a miss. Ford Techline has been contacted and no fix yet. Dont you think that Ford should with non factory warranty, replace my ecoboost????????

 

Fairly new to this forum - and new to this issue. I picked up a 2013 F150 with the EB last October that now has about 33k miles. I noticed when the temp dropped below 40-ish degrees I'd get this same rattle that lasted less than 2 seconds. I changed the oil to a full syn (pennzoil platinum) with a Purolator synthetic filter and the cold-start noise was reduced to about 1 sec on the coldest of days. I recently changed the oil again (about 5k miles) and used a mobil1 filter with the same oil and it's much louder. I recorded it and plan to take it into the dealer soon. The difference with my rattle is that it occurs immediately after the engine kicks over, whereas in the youtube clip originally posted in the thread there was a lag between the engine kicking over and the chain rattle.

I know it's a different engine, but I had a 1996 Maxima that gave me 275k great miles before I gave it to my niece - but I had to only use a Napa gold oil filter or else it would have given me a cold start rattle. I never found out what the issue was because I always used that filter and never had a problem. I'm going to switch over my next change to the Napa synthetic filter to see how that works out.

In addition, I noticed someone posted a clip about engine ticking - and my engine sounds exactly the same. I thought it just the high pressure injectors but I now don't think so. I have a 2013 Flex EB that's as quiet as a church mouse and I'm assuming the engine is identical... That's the only baseline I can use at this point.

 

I'm not seeing the camshaft phazers as a part that was replaced on the TSB 16-0027 paperwork? Any ideas on why? Am I going to have the same issue?

 

Yes you will. The cam phasers are the issue that is causing all this. There is another TSB specifically to replace them...both intake and exhaust. If not replaced it will return.

 

If they performed TSB 16-0027, then the phasers would be included in that work... also known as intake and exhaust VCT units.

 

Ah, yes, I see that now. 2 intake and 2 exhaust vct units.

 

One interesting note is they changed my 7000 interval synthetic oil change to a 5000 interval oil change. Are they acknowledging a issue?��

 

I'm having this issue with my 2011 EB. Roughly 74,500 miles. Started about a week ago, only on initial start up in the morning. Since the it is steadily getting worse. Will do it even when the engine is warmer now. Since I do not have an OBD reader, is there some other way to know if it will show the code? I have an appointment to bring it t dealer next Wednesday but I'm told that if the code isn't showing then I will be charged for the diagnostic fee.

 

I'm told that if the code isn't showing then I will be charged for the diagnostic fee.

That is old info.
For the specific issue discussed in this thread (the one that is currently being addressed under TSB 16-0027) there is no DTC fault code required.
http://www.f150forum.com/attachments...tsb16-0027.pdf

The very earliest TSB for this issue did specify a fault code, but that hasn't been the case for a long time.

Now, having said that, if you're saying that you get a noise when the engine is warm then it's possible you have a different issue. But either way you gotta start somewhere so might as well have it checked out.

I had mine looked at in March (also a 2011). They only changed the vacuum pump (under field service action 15N053). That did fix my soft brake pedal on cold start, but did not fix the cold start rattle noise.
I have another vehicle for day to day use so my plan now is to park the truck at the dealership for a few days and keep the keys with me. I will then go back and walk them out to start it with me so there can be no way that they claim to not hear the noise.

 

This issue has me scratching my head a little. I have always done my own oil changes with either royal purple or Mobil 1 oil. While using a Mobil 1 oil filter I was getting the dreaded rattle on cold starts... Not everytime but enough to make me notice. The last 3 oil changes I have used the factory Ford oil filter and have not had a single rattle on start up since. Is it just coincidence? My truck is a 13 with 57000 km, tuned for most of them my LET and MPT, UPR dual valve catch can since new and S&B intake.

Sent from my Nexus 6P using Tapatalk

 

I'd be interested to hear any thoughts on this as well. I'm a mobile 1 filter user M-212 but am not particularly tied to it. If there are some checkvalve differences or something I'd certainly be willing to try a different (or OEM) filter to stave off the dreaded clickity clackity beast. Like above poster I've had 6 rattles in the last year of ownership but I can't confidently say its getting more frequent.

 

Well, Its now been a month and a half saga. Total count 7 rentals/loaners (some have been hilarious, like the Fort Transit van). My current status/issue - all 4 VCT's replaced, new chain, belt, water pump, gasket kits, new cams, sprockets, and a bucket of additional parts. I drove it home the first day of getting it back & it sounded great. By the time I got hit home it was ticking loudly. (note, prior to taking it in i had no tick, only startup rattle). They took it back, had it 2 days later, sounded great, got home, same loud tick. They took it back. Had it a day and a half and agree there was an issue but could not find it. I was going out of town and needed a big vehicle, so the dealer did put me up in a '16 expedition.
I picked the truck up on monday. They stated the cam followers were out of spec. I drove it a couple of days (quietly) but now I hear things. Its hard to tell how paranoid I'm being at this point. GTDI is loud, but how loud is normal is still my question. Three things are now of concern.
1. At neutral idle it seems okay. At idle in gear with my foot on the brake, I hear a tick again. Sounds like from the same spot in the top end, front passenger side above the alt. I put it from D or R into N/P and it stops. this is NOT the HPFP. I get the RPM's over a grand and it stops. ANY IDEAS?
2. At idle in N/P, every so often I feel a little shake in the truck. I can see the RPM's raise/lower a couple hundred. No A/C on. No extra battery load. Fan may be on or off.
3. At around the rear drivers door standing outside I could here pressure and a "glug glug glug". It sounded to me just like an exhaust leak. I noticed water dripping from each end of the cat. Honestly I didnt know this had weep holes in it, so I suppose this is normal. It does seem to have significant pressure coming from those two small holes, enough I can hear the air. I dont have any sensors/lights indicating an issue, but now I almost wonder if there's a blockage or some kind of back pressure issue.

 

FIRST POST!!! And it's not good. Loyal Ford guy here, bought my first used 2012 Ecoboost FX4 with 79K miles in January. Short story long, I've already had the shudder/misfire issue, spent $800 out of pocket on plugs, boots, and intercooler TSBs. When that didn't fix the problem, had the throttle body replaced which seems to have fixed the problem. NOW I have the cold start rattle, and it was LOUD this morning. I'm at 83K now, so no warranties apply.

Here's where I need your help/opinions: I have a 5000 mile road trip with a trailer and the family coming up in TWO weeks. Since the repair will be all out of pocket expense, do I spend the thousands at the dealership to implement the belt/phaser changeout, use my own trusted mechanic, or even go so far as to try and trade the truck in? Backup plan would be to use my '04 Expedition for the trip instead. Ready, GO!

Thanks in advance,
David

 

Welcome to the community, KennewickMan!

My name is Tricia, and I’m one of the U.S. Ford Customer Service Representatives on this forum. We will be here to assist with any questions or concerns.

FIRST POST!!! And it's not good. Loyal Ford guy here, bought my first used 2012 Ecoboost FX4 with 79K miles in January. Short story long, I've already had the shudder/misfire issue, spent $800 out of pocket on plugs, boots, and intercooler TSBs...

Barf - sorry to hear it man. I'm in almost the same boat having crossed the 70k barrier and wondering if its going to get worse by 80k or not...

Soooo....I just had the infamous time chain rattle upon start up...

Hey Ford Family,

If your vehicles are experiencing these symptoms, we recommend that you take them to any Ford Dealership in your area. You can find a dealership, here. Be sure to PM us your VINs along with your mileages. We will be happy to see how we can best assist!

Update: had the truck back after the most recent TSB, cam phazers and timing chain replaced, had it less than a week and the truck has been at the dealership since Tuesday. It sounds like a diesel. Tech said he had never seen the issue after doing the TSB that he claims he personally has done three off...

Malinois11,

I’m just checking in on you. Was your concern resolved or is your vehicle still at the dealer?

Tricia