Hpfp?

 

Yup, just your HPFP (High Pressure Fuel Pump). Seems it took your truck a few more miles than most for the sound to start up.

 

I don't think that's the case... It's a generation 2 motor with both fuel systems and the HP FP is a used at idle when I've read... And the noise is coming from the lower end of the motor at idle and increases with RPM.

 

No matter how high you increase the RPM's, if it is Park, then it will be at idle.

 

The sound increases with RPM in Drive.

 

I'm gonna agree with the guys that said it's not HPFP related. Def sounds like something in the block not playing nice. Either rod knock, or piston slap.

 

That sounds like a spun bearing to me. I would have a dealer look at it. Any bottom end knock is usually not a good sign.

 

That kinda sounds like how my 2013 sounded before it got really loud.... Kinda

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Does it sound that way after it's warmed up? Mine seems quieter after being warmed up. Wonder if that's a good sign or bad but I've noticed the same when cold on my 2017 3.5

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The noise is louder when it's warm.




I hope it's that simple for me... It really sounds like a bottom-end knock to me though. But similar to yours mine is much more apparent when the truck is warm. And I don't hear it at all on the upper driver side Bank where the HPFP is.

The knocking noise experienced by OP is very similar, if not identical, to that noise in my 2017 2nd gen 3.5. The remedy by my dealer was replacement of both VCT "phasers" (because they could not clearly differentiate noise from the intake vrs exhaust VCT actuator) on the passenger side valve train. This fix absolutely fixed the noise and still quiet 3000 miles later. I don't believe this noise shown by the OP is anything related to the HPFP, which makes a subtle "thumping" noise clearly different than from a defective VCT actuator. As a test, the use of a simple inexpensive mechanics stethoscope can show location and type of noise difference.

My engine noise was apparent only at hot idle, and not during cold start up nor warm up; it showed up maybe 10 minutes into hot idle and thereafter. My research has now shown this issue may be a common noise issue with many 2nd gen 3.5's very often diagnosed as a HPFP issue or with no action by the dealership because there are no visible codes, no performance issues, and no Ford TSB or SSM issued to date. I am surprised that Ford has not issued a TSB to date. Keep in mind my correction required 3 trips to the Ford service dealership, with the last visit clearly communicating what I gathered from the Ford forum sites and with confirmation of noise and location by their experienced tech who also felt the noise/vibration while touching the area above the phasers near the two VCT solenoid towers and strongly suspected one of the phasers. See attached picture showing location of the phasers, which I understand were redesigned and smaller than the 1st gen 3.5. I suspect there may have been a bad batch of phasers by Borg Warner with quality issues, but could not be sure. Other forum people have concern for oil passage issues and flow to the VCT's which can cause noise issues.
View attachment 149449

 

Dealer time for sure.

Not a good sound.

 

We talk about HPFP noise a lot and rightly so because it’s a common and more often than not normal sound associated with these trucks. As far as describing a HPFP noise I think these sound more like old school lifters tapping when the valves need adjusting, a tick or tap higher up in the engine. This doesn’t sound like a HPFP to me, it is a down in the engine low sounding knock. I wouldn’t be surprised if it were a rod knock but I’ve also heard broken piston skirts sound just like a rod knock. I probably wouldn’t continue driving it until a qualified tech with a stethoscope and a good ear listened to it.

 

Listening to it again, it's definitely a hard knock vs a light tap that I'm used to

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The knocking noise experienced by OP is very similar, if not identical, to that noise in my 2017 2nd gen 3.5. The remedy by my dealer was replacement of both VCT "phasers" (because they could not clearly differentiate noise from the intake vrs exhaust VCT actuator) on the passenger side valve train. This fix absolutely fixed the noise and still quiet 3000 miles later. I don't believe this noise shown by the OP is anything related to the HPFP, which makes a subtle "thumping" noise clearly different than from a defective VCT actuator. As a test, the use of a simple inexpensive mechanics stethoscope can show location and type of noise difference.

My engine noise was apparent only at hot idle, and not during cold start up nor warm up; it showed up maybe 10 minutes into hot idle and thereafter. My research has now shown this issue may be a common noise issue with many 2nd gen 3.5's very often diagnosed as a HPFP issue or with no action by the dealership because there are no visible codes, no performance issues, and no Ford TSB or SSM issued to date. I am surprised that Ford has not issued a TSB to date. Keep in mind my correction required 3 trips to the Ford service dealership, with the last visit clearly communicating what I gathered from the Ford forum sites and with confirmation of noise and location by their experienced tech who also felt the noise/vibration while touching the area above the phasers near the two VCT solenoid towers and strongly suspected one of the phasers. See attached picture showing location of the phasers, which I understand were redesigned and smaller than the 1st gen 3.5. I suspect there may have been a bad batch of phasers by Borg Warner with quality issues, but could not be sure. Other forum people have concern for oil passage issues and flow to the VCT's which can cause noise issues.

 

The knocking noise experienced by OP is very similar, if not identical, to that noise in my 2017 2nd gen 3.5. The remedy by my dealer was replacement of both VCT "phasers" (because they could not clearly differentiate noise from the intake vrs exhaust VCT actuator) on the passenger side valve train. This fix absolutely fixed the noise and still quiet 3000 miles later. I don't believe this noise shown by the OP is anything related to the HPFP, which makes a subtle "thumping" noise clearly different than from a defective VCT actuator. As a test, the use of a simple inexpensive mechanics stethoscope can show location and type of noise difference.

My engine noise was apparent only at hot idle, and not during cold start up nor warm up; it showed up maybe 10 minutes into hot idle and thereafter. My research has now shown this issue may be a common noise issue with many 2nd gen 3.5's very often diagnosed as a HPFP issue or with no action by the dealership because there are no visible codes, no performance issues, and no Ford TSB or SSM issued to date. I am surprised that Ford has not issued a TSB to date. Keep in mind my correction required 3 trips to the Ford service dealership, with the last visit clearly communicating what I gathered from the Ford forum sites and with confirmation of noise and location by their experienced tech who also felt the noise/vibration while touching the area above the phasers near the two VCT solenoid towers and strongly suspected one of the phasers. See attached picture showing location of the phasers, which I understand were redesigned and smaller than the 1st gen 3.5. I suspect there may have been a bad batch of phasers by Borg Warner with quality issues, but could not be sure. Other forum people have concern for oil passage issues and flow to the VCT's which can cause noise issues.
View attachment 149449

Sounds a lot like the same issue I had with my old 2013 3.5 ecoboost

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One more point regarding "peformance issues"; I think as a result of the VCT replacement my "percieved" mpg did increase back to that found when the truck was new. Just a thought to keep in mind, but understanding that MPG can be a very subjective evaluation.

 

On the 2017 2nd gen 3.5, the HPFP is located mid point on the Rt side "passenger" side valve cover not the Driver side. Please see my posted picture for that location. My noise was indeed more noticeable when the engine was warm and at operating temp. Keep in mind that I have found that the use of the simple mechanics stethoscope will help you to understand the true location of the noise. I really don't think your knocking noise is the HPFP. Have your local dealership service dept make that determination.