2025 2.7L engine replacement

[b-smi91]

50 year Ford tech. Ordered new Ranger to my specs. July 2025 took delivery. Using coolant since new.

February 2025 diagnosed with coolant intrusion into combustion chambers. Chemo treatments forbade me from performing repairs.

New engine installed by fellow tech. (Top notch). Now has phaser rattle on every start up. Bought new so wouldn’t have to work on my own.

Working with Ford on buy back. 2.7L is a great engine, not mine.

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[They Call Me Bruce]

oh geez, that really sucks. Obviously you got a Lemmon, hope the buy back goes well.

 

[HighDesertRanger]

So you’ve had not one, but two, bad 2.7L engines in this truck?

I feel for you. This has to be some of the worst luck ever. The 2.7L ecoboost is generally one of Ford’s most reliable motors.

I hope they get you sorted out soon.

 

[Jason B]

50 year Ford tech. Ordered new Ranger to my specs. July 2025 took delivery. Using coolant since new. February 2025 diagnosed with coolant intrusion into combustion chambers. Chemo treatments forbade me from performing repairs. New engine installed by fellow tech. (Top notch). Now has phaser rattle on every start up. Bought new so wouldn’t have to work on my own. Working with Ford on buy back. 2.7L is a great engine, not mine.

AFAIK, cam phaser rattle for a few seconds on cold start seems to be the norm.
Let Ford buy it back.

 

[superj]

wow!! that is terrible to have to go through. i had to go through the engine replacement on my last truck, a 2017 nissan titan, at 3 months of ownership so i know how you feel on that part of it though now the second engine is also bad is a double whammy.

i hope whatever you get next turns out to have zero issues to make up for this.

 

[danmoochie]

Wow sounds like my 24 RR that had cam phaser failure at 900 miles, i just dumped it, not going through all that on a RR I paid a ton for, good luck.

 

[b-smi91]

AFAIK, cam phaser rattle for a few seconds on cold start seems to be the norm.
Let Ford buy it back.

Definitely not normal

 

[CptPrice]

I really feel for you. That phaser rattle on a brand new engine is definitely not normal. Good luck with the buyback.

 

[Lifefoce]

I feel your pain, Barry. That double engine trouble is rough. I'd push hard for the buyback too. Good luck

 

[boraxman]

Is there any update? Was the buyback successful?

 

[b-smi91]

Is there any update? Was the buyback successful?

No. Then the new engine rattled on startup! Resubmitted buy back and it was denied. Offered me a maintenance policy instead. Sold to Carvana. Bought a 2.3L.

 

[landiscarrier]

That’s pretty lousy. I think Ford should do a better job taking care of their employees. They should have worked with you.

 

[Lion77]

Got any videos of the phasor rattle on the new engine? Coolant intrusion is an obvious one, but I've seen several videos of people saying they have phasor rattle that aren't actual phasor rattle. The HPFP is VERY rattly on start-up.

In cold weather, my Mazda 2.5 Turbo in my wife's CX-9 sounded like a diesel engine, especially under load at idle (like just creeping forward by letting off the brake but not hitting the gas). Once it warmed up it was back to sounding like a well oiled sowing machine. At first, I thought it had piston slap, but then realized it was the HPFP when cold. Most of them are four lobe, with a looser cam tolerance, so they tend to have a very rattly / knocky sound, almost like diesel piston rattle.

My RR is very rattly when it starts up, and under certain conditions I get a bit of rattle even when warm when I turn the AC on at idle under load (as in its in drive, but brake is on, so engine is loaded by the torque converter and AC compressor).

I suspect it's the HPFP lobes; they have a loose tolerance and operate at high pressure even when at idle. Truck runs like a champ though and its purrs as RPM climbs but sounds like a diesel on cold start, just like my wife's 2.5L Turbo. Heck even my 2.5L NA engine in my 3 uses a HPFP since it's DI, it's quite rattly too on startup and it's not even a turbo engine.

These aren't the engines of the 1990's or early 2k which were much quieter on startup. Modern TDI engines have all kinds of clatter, HPFP, 2k PSI injectors, stiffer valve springs, stricter emissions requirements that force certain valve timing during startup with overlap etc.

We just traded in the CX-9 for a smaller more fuel efficient CX-50 that has only 12k miles on it and she asked me if there was something wrong with her engine on a cold start because it was clattery. I told her it sounds exactly like my 3 that has 75k miles and her CX-9 that she just got used to.

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