USA Ranger Raptor Cold Start Rattle at 7 Miles!

[Barney the Purple Ranger]

This past week the Ranger Raptor I ordered last June finally arrived at the dealer. When I went to pick it up I recorded the salesman cold starting the truck. I took the truck for a test drive and everything seemed okay. I filled out the paperwork and had everything ready except for the payment. Since the bank was closed for the week I decided I'd stop back on Monday to pay. When I got home I watched the clip of the startup and to my surprise I heard what sounded like cam phaser rattle.

I asked a co-worker with a 150,000 mile 2018 F-150 with the 2.7 "Nano" V6 for a cold start video to see if the rattle was present on his truck being the 2.7 V6 is a de-bored and de-stroked version of the 3.0 V6 present in the current Ranger Raptor. His truck does not rattle on startup.

When I got to the dealer on this Monday I asked to have a dealer tech listen to the vehicle start. Since the vehicle had sat over the weekend I figured this would be the perfect opportunity to see if the noise still existed. To my dismay the rattle upon startup was still present and the tech agreed that the rattle did sound like a failed cam phaser. We went back to the service desk and showed both videos to the service writer. Later that day the service department pulled the truck into the service bay and ordered all 4 cam phasers (4 days out) for the truck per my salesman.

I emailed the next day that I was uncomfortable about having a new engine disassembled because of the potential for leaks on the seals, gaskets, and hoses disturbed during the repair. I asked via email if I would receive any kind of additional warranty because of the phaser failure (and the probability that the replacement parts would likely be the same faulty part no. and revision) and was told no. I called the salesman back and he said that the Bronco Raptor on the lot exhibited the same sound upon startup and that the sound seemed "normal" there was "probably nothing wrong with the truck." At this point I pulled the plug and walked away.

Yesterday the truck was relisted for "Immediate Delivery" on the dealer's Facebook page before the phaser parts would even be in for the repair. This made me sick to my stomach to think they would push this off on someone who doesn't know any better. Has anyone else experienced this sound on cold startup (24hrs+ parked) in their Ranger Raptor?

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[yoopercharged]

What a major disappointment. Sorry this happened to you. I was really hoping the NA trucks were going to have this issue resolved.

 

[Barney the Purple Ranger]

I think what's most disappointing is that Ford has been struggling to offer a reliable phaser design for 20 years now. Seems hit and miss the exact years and models it impacts; some are certainly worse than others. Whether it be the design, material composition, or supplier workmanship of the camshaft phasers it's time that Ford gets this under control. Almost all new cars have some sort of variable valve timing system and don't seem to exhibit this problem.

I'll be waiting to see how prevalent this issue is with these trucks (Bronco and Ranger Raptor specifically) going forward before I decide if I want to reorder. If I was thinking a little harder I would have got more details on the production date codes on the engine, sorry guys. If someone knows how to get this data from the ordering info maybe I can be of some help.

Blend : 3/18

Moved into production: 3/11/2024
Built: 3/22/2024
Shipped: 3/23/2024
Arrived at dealer: 4/3/2024
Final Preparation: 4/4/2024

 

[yoopercharged]

I think what's most disappointing is that Ford has been struggling to offer a reliable phaser design for 20 years now. Seems hit and miss the exact years and models it impacts; some are certainly worse than others. Whether it be the design, material composition, or supplier workmanship of the camshaft phasers it's time that Ford gets this under control. Almost all new cars have some sort of variable valve timing system and don't seem to exhibit this problem.

I'll be waiting to see how prevalent this issue is with these trucks (Bronco and Ranger Raptor specifically) going forward before I decide if I want to reorder. If I was thinking a little harder I would have got more details on the production date codes on the engine, sorry guys. If someone knows how to get this data from the ordering info maybe I can be of some help.

Blend : 3/18

Moved into production: 3/11/2024
Built: 3/22/2024
Shipped: 3/23/2024
Arrived at dealer: 4/3/2024
Final Preparation: 4/4/2024

I’m sure you’re aware that the Gen 2 F150 Raptor also suffered from cam phaser issues. Seems like they were finally able to get it right on the Gen 3 in 2021. What surprises me the most is that they’ve likely been on that phaser revision for 5+ years now and haven’t been able to apply those lessons learned to other powerplants.

You’re totally right, there’s no excuse for this to still be a probably that customers are dealing with so many years later.

 

[ivotuk]

Wow! That's disturbing! I've worked on older engines, and have quite a bit of experience with gas and diesel, and that sounded horrible!
Thank you for posting those. I'll listen for that when I pick mine up in Louisiana Mid-May. Don 't need it crapping the bed somewhere between here and North Pole, Alaska.

 

[cc1999]

I’m sure you’re aware that the Gen 2 F150 Raptor also suffered from cam phaser issues. Seems like they were finally able to get it right on the Gen 3 in 2021. What surprises me the most is that they’ve likely been on that phaser revision for 5+ years now and haven’t been able to apply those lessons learned to other powerplants.

You’re totally right, there’s no excuse for this to still be a probably that customers are dealing with so many years later.

I am not familiar with this issue at all. Just now learning about it.
Does this mean we should all expect this rattle at startup with all the new Ranger Raptors or is this just an isolated issue that there is a fix for under warranty?????

My 2.7 EB in my Bronco is the Ford EcoBoost vehicle I have ever owned, I am very much a V8 guy, but have started making the occasional exception for vehicles I really like and want to own, like my 2 door Bronco, and this new Ranger Raptor I am hoping to get in the next week or two.

 

[mkerptr]

Same thing happened on my ‘23 Bronco Raptor… 500 miles in. Full engine out, can phaser replacement. ??

Hope they can do a buyback or give you a huge pain&suffering discount.

 

[yoopercharged]

I am not familiar with this issue at all. Just now learning about it.
Does this mean we should all expect this rattle at startup with all the new Ranger Raptors or is this just an isolated issue that there is a fix for under warranty?????

My 2.7 EB in my Bronco is the Ford EcoBoost vehicle I have ever owned, I am very much a V8 guy, but have started making the occasional exception for vehicles I really like and want to own, like my 2 door Bronco, and this new Ranger Raptor I am hoping to get in the next week or two.

I wouldn’t say you should expect it, but know that it’s a very real possibility. It will be covered under your powertrain warranty but it’s a pretty extensive process that required the engine to be tore apart.

 

[Barney the Purple Ranger]

I am not familiar with this issue at all. Just now learning about it.
Does this mean we should all expect this rattle at startup with all the new Ranger Raptors or is this just an isolated issue that there is a fix for under warranty?????

My 2.7 EB in my Bronco is the Ford EcoBoost vehicle I have ever owned, I am very much a V8 guy, but have started making the occasional exception for vehicles I really like and want to own, like my 2 door Bronco, and this new Ranger Raptor I am hoping to get in the next week or two.

There was a TSB (Technical Service Bulletin) from Ford for early Ford Explorer / Lincoln Aviator 3.0l EcoBoost/PHEV vehicles that gives a brief explanation of the problem and the fix.

NHTSA 3.0 EcoBoost TSB

Here is a nice general video that shows the issue if anyone would like to know more :
EcoBoost Cam Phaser Rattle/ The noise, The cause, The fix
While this particular video shows a 3.5L EB, the failure condition is the same across all ford V6 and V8 DOHC engines within the last decade.

As explained in the original post the problem existed on both the Braptor and RR at the dealer I ordered to. Beyond that only @JimmyRR on the forum reported this issue in a RR.

 

[Barney the Purple Ranger]

Same thing happened on my ‘23 Bronco Raptor… 500 miles in. Full engine out, can phaser replacement. ??

Hope they can do a buyback or give you a huge pain&suffering discount.

No buyback necessary as I backed out on the deal before money switched hands. I feel bad for the new owners; as the dealer never addressed the issue on either raptor on the lot. The day after I backed out of the deal they listed truck I ordered for "Immediate Delivery" before new phasers would have arrived at the service department. I don't anticipate this dealer will perform the repairs.

 

[danmoochie]

Same thing happened on my ‘23 Bronco Raptor… 500 miles in. Full engine out, can phaser replacement. ??

Hope they can do a buyback or give you a huge pain&suffering discount.

HOW LONG DID IT TAKE, AND IS IT FIXED? OR DID YOU DO A BUY BACK> i AM IN SAME BOAT WITH 900 MILES.... UGH

 

[08mojo]

This past week the Ranger Raptor I ordered last June finally arrived at the dealer. When I went to pick it up I recorded the salesman cold starting the truck. I took the truck for a test drive and everything seemed okay. I filled out the paperwork and had everything ready except for the payment. Since the bank was closed for the week I decided I'd stop back on Monday to pay. When I got home I watched the clip of the startup and to my surprise I heard what sounded like cam phaser rattle.

I asked a co-worker with a 150,000 mile 2018 F-150 with the 2.7 "Nano" V6 for a cold start video to see if the rattle was present on his truck being the 2.7 V6 is a de-bored and de-stroked version of the 3.0 V6 present in the current Ranger Raptor. His truck does not rattle on startup.

When I got to the dealer on this Monday I asked to have a dealer tech listen to the vehicle start. Since the vehicle had sat over the weekend I figured this would be the perfect opportunity to see if the noise still existed. To my dismay the rattle upon startup was still present and the tech agreed that the rattle did sound like a failed cam phaser. We went back to the service desk and showed both videos to the service writer. Later that day the service department pulled the truck into the service bay and ordered all 4 cam phasers (4 days out) for the truck per my salesman.

I emailed the next day that I was uncomfortable about having a new engine disassembled because of the potential for leaks on the seals, gaskets, and hoses disturbed during the repair. I asked via email if I would receive any kind of additional warranty because of the phaser failure (and the probability that the replacement parts would likely be the same faulty part no. and revision) and was told no. I called the salesman back and he said that the Bronco Raptor on the lot exhibited the same sound upon startup and that the sound seemed "normal" there was "probably nothing wrong with the truck." At this point I pulled the plug and walked away.

Yesterday the truck was relisted for "Immediate Delivery" on the dealer's Facebook page before the phaser parts would even be in for the repair. This made me sick to my stomach to think they would push this off on someone who doesn't know any better. Has anyone else experienced this sound on cold startup (24hrs+ parked) in their Ranger Raptor?

What vehicle is in the 3rd video? Is it the new Ranger Raptor that was in the 1st video?

The first one is not nearly as pronounced--and my RR sounds very similar. I've also heard the wastegates can make a similar noise at startup, but not as loud or violent as the cam phaser.

If you've ever heard the cam phaser failure in person on a cold start, it is not a question of maybe or maybe not--it's violent!! That makes me wonder if the noise on the RR is normal?

 

[Barney the Purple Ranger]

What vehicle is in the 3rd video? Is it the new Ranger Raptor that was in the 1st video?

The first one is not nearly as pronounced--and my RR sounds very similar. I've also heard the wastegates can make a similar noise at startup, but not as loud or violent as the cam phaser.

If you've ever heard the cam phaser failure in person on a cold start, it is not a question of maybe or maybe not--it's violent!! That makes me wonder if the noise on the RR is normal?

In my initial post the vehicle pictured in the first and third video is the same 2024 Ranger Raptor that I special ordered. In the third video you can tell by the engine decal next to the hood prop rod "stay clip" that the vehicle is indeed a Ranger Raptor. It specifies (2.3L GTDI) (2.7L / 3.0L GTDI)
Of all the NA FoMoCo products that feature the 3.0 EcoBoost V6:
The engine decal on the Bronco Raptor only specifies the 3.0L GTDI and the engine bay lacks a hood prop
The Ford Explorer/Lincoln Aviator don't offer a 2.7L GTDI
The Lincoln MKZ did not have the option for the 2.7L GTDI and engine is transverse
The Lincoln Continental did not have an option for a 2.3L GTDI and engine is transverse

If left unchecked the phaser sound will devolve to sound like this 1st Gen F-150 3.5L EcoBoost.

The Ranger Raptor makes the same sound but not yet in an advanced state.

I can say from firsthand experience with a 1st gen EcoBoost in a 2012 F-150 and a transverse 3.5L EcoBoost in a 2014 Lincoln MKT (both with over 100k mi) that cold start rattle is not a normal. In both of my vehicles the valvetrain is silent. The same goes for friends with both 2.7L and 3.5L EcoBoost in F-150s and family and friends who have or had Ford 3.5L and 3.7L Cyclone V6s which are the basis for the 3.5L EcoBoost.

Wastegate rattle on my 2012 F-150 tends to occur when boost pressure builds under mild to moderate acceleration. Atmospheric conditions and engine temperature seem to have little effect on the sound of the rattle or the event frequency.

On the Ranger Raptor I ordered the cam phaser sound only occurred after a day of "cold soak" and was not present under other operating conditions. The reason for this is as the vehicle sits oil pressure that holds the phaser in a neutral position (away from the ends of phaser travel in advance or retard of the center locking position) bleeds down. Without oil pressure and a faulty locking pin (that otherwise would lock the phaser under engine shutoff until oil pressure is restored shortly after startup) the fins of the phaser are allowed to violently contact either end phaser travel when the vehicle is restarted.

Might be easier to understand by looking at this video starting at the 11 minute mark.


Hope this helps.

 

[danmoochie]

best explanation and video yet. I am still waiting on Ford to decide if I am getting a new drop in motor or cam phaser replacements, and if I get the replacements, I am hoping they are indeed different (upgraded) like shown here.

 

[BlckHwk23]

Well it’s been fun guys. Made the hard choice to walk away from the Ranger Raptor today. Too much uncertainty on the wait for parts, future reliability, and support from Ford. Hope everyone’s journey turns out better than mine

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