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Discussion Starter #1
Bought my 2016 F150 2.7 as a CPO last August (2019). Unfortunately in my research I didn't come across the leaky 2.7 oil pans until after purchase. At first glance I kneel and and take a look...there she blows. It's even harder to catch on mine because of the FX4 skids.

In October I had Ford do a warrantied replacement with extremely specific instructions. I did extensive research on what "worked" for others and Ford played along. We let the block drain from Tuesday - Friday, and let the new pan cure from Friday - Monday before putting oil in to ensure the seal. I was told a 2 year warranty on the work from Ford.

Decided to take a look last weekend (roughly three months later) and the whole thing is saturated again. Oil level is fine, still sitting near max, but what gives? Is it really impossible to seal?

My official questions are this:
1) Are there any long-term success stories of the poly-oil pan getting replaced and NOT leaking?
2) I know there's an aftermarket upgrade for the solid alum out there. More than willing to do that, but does anyone know what affect that might have on the powertrain warranty?

All opinions and comments appreciated. Fellow owners who want to share their pain also appreciated (make me not feel so alone here).
 

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Not mine it's dry as new with 30000 miles on it now. From what I have found out is that it's a problem with out of specification mold run resulting in old stock from the bad lot being used.
Figure I got a good one. For what it's worth that is about the only regularly reported problem with the 2.7. KM
 
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We have a couple of 2.7's, both 2016's.

One of them got a new oil pan somewhere around 25,000 miles. It was the service department that noticed the leak during an oil change. Handled through warranty.

It's been better than a year and seems to be good.

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Discussion Starter #5
We have a couple of 2.7's, both 2016's.

One of them got a new oil pan somewhere around 25,000 miles. It was the service department that noticed the leak during an oil change. Handled through warranty.

It's been better than a year and seems to be good.

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That's hopeful. I'd just love to know what went different. We let mine dry completely and cure completely, not sure what else can be done in the process to ensure it wont leak...but that's what I'm looking for.

To me, a bad lot makes sense in a vacuum but across this many vehicles and years seems unlikely. Material lots are typically small batches (for this exact reason) and dont take years to purge from stock. OR...I'm just the most unlucky person on the earth and got a new pan, 3 years later, from the same lot batch mine was made from. Again possible but so unlikely.

Does anyone know if swapping the pan to an aftermarket one will void powertrain?
 

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You can check out this YouTube video on the replacement if you’d like. Been a while since I watched it but IIRC a fast cure sealant was used.
 

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Excellent video.

You gotta be READY once that RTV is applied!
I'm guessing that's got a limited margin of error to consider. And I'm also betting some percentage of installs weren't within those limits?

One-time-use was news to me as well.

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As this seems to be a repeat problem for more than 1 or 2 owners, I was wondering if anyone had considered making their own fiber material gasket. I know that’s a pretty outdated concept by todays standards but my head tells me it just might be worth a try.
 

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Discussion Starter #10
As this seems to be a repeat problem for more than 1 or 2 owners, I was wondering if anyone had considered making their own fiber material gasket. I know that’s a pretty outdated concept by todays standards but my head tells me it just might be worth a try.
I'm open to all options. I've removed and reinstalled many pans in my day, although none were poly-based. A good cleaning, a good RTV and patience during cure is typically good enough to hold fine.

My main concern would be not violating the powertrain warranty. As crappy as losing the truck for a week every year might be, its not worth losing the entire warranty in my opinion. Anyone have any input on that?
 

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Think that was on the 3.5. I haven’t heard of a metal pan for the 2.7.
 

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My 2015 2.7 has 169,000 miles on it. I’ve replaced the drain plug twice but that’s the only leak issue , other than the trans pan, that I’ve had.
 

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Discussion Starter #15
Not totally related to the title, but excuse me while I vent.

Ford finally called, no issue with the oil pan fix (although they did it incredibly fast, so it'll prob leak again), but he's saying the sunroof FRAME is bent/twisted, and since they only replaced the arms last time, its technically not covered. I feel this is dubious, as failure of the arm could result in frame warpage.

Obviously I'm fighting it. Warranty on the CPO fell out 30 days ago, but this issue existed with the purchase of the car, and was last touched by Ford 1 month post-purchase. Hopefully this pans out in my favor. We shall see.
 

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Bought my 2016 F150 2.7 as a CPO last August (2019). Unfortunately in my research I didn't come across the leaky 2.7 oil pans until after purchase. At first glance I kneel and and take a look...there she blows. It's even harder to catch on mine because of the FX4 skids.

In October I had Ford do a warrantied replacement with extremely specific instructions. I did extensive research on what "worked" for others and Ford played along. We let the block drain from Tuesday - Friday, and let the new pan cure from Friday - Monday before putting oil in to ensure the seal. I was told a 2 year warranty on the work from Ford.

Decided to take a look last weekend (roughly three months later) and the whole thing is saturated again. Oil level is fine, still sitting near max, but what gives? Is it really impossible to seal?

My official questions are this:
1) Are there any long-term success stories of the poly-oil pan getting replaced and NOT leaking?
2) I know there's an aftermarket upgrade for the solid alum out there. More than willing to do that, but does anyone know what affect that might have on the powertrain warranty?

All opinions and comments appreciated. Fellow owners who want to share their pain also appreciated (make me not feel so alone here).
My 2015 2.7 has been great with 77000 miles except for the oil pan leak. Had it replaced at 30K and just found it leaking today. Back to Ford. My year extended warranty expired 9/17. Better not be no fuss or muss.
 

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Discussion Starter #17
My 2015 2.7 has been great with 77000 miles except for the oil pan leak. Had it replaced at 30K and just found it leaking today. Back to Ford. My year extended warranty expired 9/17. Better not be no fuss or muss.
Lol, I really dont want to share my conclusion on the sunroof here then...

But for the pan, idk. Ford also has 2year warranty on parts. So I'd imagine if your pan was replaced less than 2 years ago, youd be covered whether vehicle warranty is in place still or not. If not, I'd still fight it, the leak is crazy common, even moreso then sunroof issues. Someone on another forum mentioned having them checking the block for alignment. I will probably have them do that next time as I'm sure there will be one..
 

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Thinking mine was replaced 2-3 years ago so, hopefully, it will be within the window. Will make some noise if they try to worm out of it and see if Ford still has District Service Managers, as they once did. Good luck with your problems!
 

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Discussion Starter #19
Thinking mine was replaced 2-3 years ago so, hopefully, it will be within the window. Will make some noise if they try to worm out of it and see if Ford still has District Service Managers, as they once did. Good luck with your problems!
Thanks, mine are all resolved now. Obviously didn't pay for the pan issue, but did have to cough up for the sunroof. Sucked. Ford chipped in some. What can you do...

As you said, trucks been great otherwise.
 

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Registered just to post - I have a 2017 Sport with the 2.7 Ecoboost. I'm the second owner, purchased in May. Had the oil pan replaced by the dealer I bought it from just before I purchased it. Found a leak about a month later - local non-dealer shop suggested taking it to a different dealer. They replaced it a *second time. Was fine for a month - leaking again. The second dealer contacted Ford and Ford told them to pull the engine and replace the skirt and lower crankcase - apparently the first dealer didn't follow the service guide and used a tool to pry the oil pan off and damaged the skirt.

This is being done this week - will post when i get it back and let everyone know how it went - I have concerns with the engine being split but we'll see.
 
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