My Issues Post Cam Phaser Replacement

[Eship]

Update

The saga continues. Truck makes a loud "cam phaser" clacking noise on cold start. It also makes the noise after being parked for 20+ minutes after bringing engine to running temp. On cold start, the noise starts off faint or it can't be heard and then gets louder and becomes pronounced once the truck transitions from high idle and settles into normal idle. If left to idle, the truck will exhibit the loud clack for about one minute after idle transition and then the noise goes away. If you cold start and then drive off, the sound will come on and then fade off within a span of about 20 seconds. While driving off cold (parking lot speed) the clacking sound turns into a clicking sound that I can only compare to a big game fishing reel that has been set to free spool + clicker. Similar symptoms are exhibited while engine is hot and after being parked for 20+ minutes except more abbreviated.

Another note, the truck did not start making the cam phaser noise until the end of the first day after retrieving the truck from the dealer. So, there were at least two heat cycles and maybe half a dozen start-ups before the clacking sound came on.

As stated in previous posts, my truck began exhibiting cam phaser noise before I sent it in for the initial warranty service appointment, but it was very faint. The noise is loud now.
Truck has no check engine light, but is displaying DTC P0021. For the most part, the truck performs/drives normally, but I can feel some slight hesitations/stumbles intermittently under moderate throttle scenarios.

Truck goes back to the shop tomorrow. Will report back what info I gather.

 

[Eship]

Truck is in the middle of being torn down again. Should be done early next week. Will report.

 

[FordTechOne]

Update

The saga continues. Truck makes a loud "cam phaser" clacking noise on cold start. It also makes the noise after being parked for 20+ minutes after bringing engine to running temp. On cold start, the noise starts off faint or it can't be heard and then gets louder and becomes pronounced once the truck transitions from high idle and settles into normal idle. If left to idle, the truck will exhibit the loud clack for about one minute after idle transition and then the noise goes away. If you cold start and then drive off, the sound will come on and then fade off within a span of about 20 seconds. While driving off cold (parking lot speed) the clacking sound turns into a clicking sound that I can only compare to a big game fishing reel that has been set to free spool + clicker. Similar symptoms are exhibited while engine is hot and after being parked for 20+ minutes except more abbreviated.

Another note, the truck did not start making the cam phaser noise until the end of the first day after retrieving the truck from the dealer. So, there were at least two heat cycles and maybe half a dozen start-ups before the clacking sound came on.

As stated in previous posts, my truck began exhibiting cam phaser noise before I sent it in for the initial warranty service appointment, but it was very faint. The noise is loud now.
Truck has no check engine light, but is displaying DTC P0021. For the most part, the truck performs/drives normally, but I can feel some slight hesitations/stumbles intermittently under moderate throttle scenarios.

Truck goes back to the shop tomorrow. Will report back what info I gather.

I’m suspecting that there is engine bearing damage causing a lack of sufficient oil pressure to the VCT system. The first place to check is the front camshaft journals (mega caps); if they’re scored, oil pressure will bleed off. The scoring is the result of lack of oil changes, poor quality oil/filter, or running the engine low on oil. Let us know what they come up with.

 

[Eship]

Update - dealer says they found a faulty timing chain tensioner and that is the cause of the noise. Stopping by dealer after work to take a look at the truck. Let me know your thoughts about this and also what else should be checked in way of a "faulty tensioner".

 

[FordTechOne]

Update - dealer says they found a faulty timing chain tensioner and that is the cause of the noise. Stopping by dealer after work to take a look at the truck. Let me know your thoughts about this and also what else should be checked in way of a "faulty tensioner".

Sounds like they found the issue. If a tensioner fails it will make a similar sound to a failed phaser when starting. It results in excessive chain slack, which matches your description of the noise it was making and will also set timing DTCs. As long as no other components were damaged, only the tensioner needs to be replaced.

 

[Eship]

Sounds like they found the issue. If a tensioner fails it will make a similar sound to a failed phaser when starting. It results in excessive chain slack, which matches your description of the noise it was making and will also set timing DTCs. As long as no other components were damaged, only the tensioner needs to be replaced.

Copy. Thanks.

 

[Eship]

Update

Picked up the truck on Wednesday. I will summarize via quoting the notes on the service invoice. They are oddly legible when compared to previous service invoice notes. See quote below:


"Vehicle exhibited characteristics of engine noise at startup, rattle type, tick as outlined in TSB 21-2119. While inspecting the vehicle it was noticed that the noise remained through all rpm ranges of driving. Inspected axial and radial play in both turbo shafts and found no compressor wheel contact with housing. Connected IDS to scan for codes. Used pid recorder during test drive. Found code P0016. Performed PPT for VCT solenoid operation and base engine oil pressure as outlined in WSM for this code. Improper VCT movement but solenoid tested ok. Base oil pressure was low at 12-16psi at normal operating temperature at 1500 rpm. Specs are 20-30psi. Upon removal of the engine timing cover, found bank one timing chain tensioner not applying tension to the timing chain guide. Checked timing on the engine and found bank 1 to be 1 tooth off between intake and exhaust phasers. Removed components and found bank 1 timing chain tensioner plunger would not seat and seal inside of its housing. This would cause no oil and oil to leak around the plunger causing a low oil pressure concern. Replaced both tensioners, both chains and all 4 VCT units for low oil pressure and engine noise concerns with additional oil change. Re-tested with test drive cold and hot through all rpm ranges and found no other additional concerns at this time. additional noise may be heard during acceleration and deceleration from the turbos and are normal as outlined in TSB 20-7092
212119B
12650D
6600BA
12650D81
12650D45"


The truck is running and driving normally at this time. The only thing wrong with the truck at this time is the horn is inoperative. I hope the horn issue is just someone ******** with me. I could maybe even chuckle at that. In any case, it's just more icing on the embarrassment cake.

I will report back with further info.

 

[Eship]

Update

I've put about a thousand miles on the truck since last service. Truck seems to be running and driving normally or close to it. I decided to check the truck for codes tonight for the first time since last service. I'm getting two DTCs, but no check engine light or MIL messages via FordPass app. Codes below.

P2602
P06DA

from a very cursory couple of minutes google searching, it seems as though these codes are more than likely sensors that are unplugged or not fully seated. P2602 being cooling pump and P06DA being the oil pump. Anyhow, I'm going to poke around in the engine bay and see what there is to see. I wouldn't be surprised to see sensor pigtails disconnected since this has already happened during this series of dealer services. I'm not sure where exactly to find these items/sensors, but it shouldn't be difficult with some googling.
If any of you have had personal experience with these codes, I'd like to hear from you, please.

thanks

 

[KODIAK]

How have you been making out since?

 

[ffirgriff]

I’d also like to know how the trucks been running since.

I’m having the exact same problem. Cam phasers replaced 12/17/21. Parked truck after picking it up that night and started it roughly an hour later to run an errand and it is making a god awful clicking/ticking/ratcheting noise. It appears to only do it once it’s been warmed up and then sat for at least a half hour. Overnight cold starts caused only a very slight phaser rattle but hardly noticeable.

Took it back to my dealer 12/20/22. They’ve been unable to replicate it somehow and claim they’ve tried every day to make it happen. I opened a case with Ford and they had an engineer contact my dealer yet nothing was resolved because the issue can’t be replicated. Ok so tonight, after 25 days, I go pick it back up since they can’t figure it out anyway. I did the same exact scenario, get home and park it for an hour, start it up, and the same noises are present. “Cannot replicate concern” my ***.