Powerboost squeal when going electric to ICE - Help me!

[backcountryplatinum]

Hi everyone, I have a squeal noise that comes from the middle of the truck when the vehicle goes from 0.0 battery idle to 1.5+ RPM in ICE.

Dealership first said its the TSB for transmission, then the foreman said its actually the turbo actuator and replaced both turbos! Noise persist and with the hot weather is actually getting louder and more frequent. When it was -15+ you couldn't hear it.

Nobody can figure it out.

Here are 2 videos of the noise, you can hear the distinctive squeak/squeal.

-> Noise at 1 second, 9 seconds, 13 seconds, 18 seconds, and the loudest at 25. I am just throttling the gas after it idles down to electric.

-> Noise at 2 seconds, 21 seconds, 34 loud.

Thanks all

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[HammaMan]

That's normal. You're hearing your electric motor connected to the torque converter. The slight squeak I believe is the TC to ICE clutch engaging / disengaging (ICE fire, speed match, clutch engage ---- clutch disengage, ice shutdown, electric motor spin down if not in gear). It also sounds like the exhaust heat exchanger is moving as well in the second video. You can hear the exhaust note change when the heat exchanger is open / closed. When exhaust is diverted through it the exhaust muffles a little bit and you should be able to see it operate the flap (under passenger side).

To get a better sense of the noises, w/ HVB charged (when ICE shuts off) and no noises are heard while in P, put it into R and you should hear the electric motor spin up. After a few seconds if you're sitting on the brakes it may spin down in R (does in drive like sitting at a light). If you familiarize yourself with noises w/out the ICE running, when the ICE fires and it engages the clutch you can begin to familiarize yourself with its various noises. What I'm hearing there is within normal operational noises and of no concern.

 

[backcountryplatinum]

That's normal. You're hearing your electric motor connected to the torque converter. The slight squeak I believe is the TC to ICE clutch engaging / disengaging (ICE fire, speed match, clutch engage ---- clutch disengage, ice shutdown, electric motor spin down if not in gear). It also sounds like the exhaust heat exchanger is moving as well in the second video. You can hear the exhaust note change when the heat exchanger is open / closed. When exhaust is diverted through it the exhaust muffles a little bit and you should be able to see it operate the flap (under passenger side).

To get a better sense of the noises, w/ HVB charged (when ICE shuts off) and no noises are heard while in P, put it into R and you should hear the electric motor spin up. After a few seconds if you're sitting on the brakes it may spin down in R (does in drive like sitting at a light). If you familiarize yourself with noises w/out the ICE running, when the ICE fires and it engages the clutch you can begin to familiarize yourself with its various noises. What I'm hearing there is within normal operational noises and of no concern.

Hi! Thanks for the intel. 2 things I will add - the squeak is very loud. We were camping on Monday and was using the truck to power something and when the ICE kicked on and made the squeak we all turned and looked. The dealership also said it sounded out of the ordinary, did the turbo thing and I haven't been back (going next week) as they got hacked and couldn't accept new folk.

Is there something in that chain of events above that could need a replacement, grease, etc? Thanks.

 

[HammaMan]

I'd start with the heat exchanger on the exhaust. There's a flap / actuator that diverts the exhaust flow through the heat exchanger for heating up coolant faster. When cool, feel around on it and you should get an idea of it.

Might try something simple like WD40 to see if that narrows down your noises. That is exhaust which gets hot AF so a dry lube might get you somewhere in the long run, but something like WD40 for reducing the variables may help short-term.

That's got a little flap that opens/closes to divert exhaust into the ridged area for heating. That may be a squeak point.

Otherwise to get to the clutch assembly the trans and everything behind it has to come out. That's not a small job to get to the hybrid clutch assembly.

 

[WA_502A]

Little hard to tell from your video but I second HammaMan.

I have a 2022 Lariat that was making a very loud "chirp" every time it transitioned from ICE to EV. At first, the dealer couldn't "replicate the issue" so I had to go for a drive with the tech. Once I demonstrated the issue and specifically asked them to check the heat exchanger valve I was able to get it replaced under warranty.

No more chirp. Milage has also improved since having it replaced. That could be unrelated but I was averaging 18-19 before and have since been getting 20-22.

I can DM you a copy of the report with all the notes if that would be helpful to show your dealer.

 

[backcountryplatinum]

I'd start with the heat exchanger on the exhaust. There's a flap / actuator that diverts the exhaust flow through the heat exchanger for heating up coolant faster. When cool, feel around on it and you should get an idea of it.

Might try something simple like WD40 to see if that narrows down your noises. That is exhaust which gets hot AF so a dry lube might get you somewhere in the long run, but something like WD40 for reducing the variables may help short-term.

That's got a little flap that opens/closes to divert exhaust into the ridged area for heating. That may be a squeak point.

Otherwise to get to the clutch assembly the trans and everything behind it has to come out. That's not a small job to get to the hybrid clutch assembly.

Thanks. Ill try that tomorrow.

If its the clutch assembly, would it be a belt in there? Ill push them to get it fixed. Anywhere else you think I should take a look?

Little hard to tell from your video but I second HammaMan.

I have a 2022 Lariat that was making a very loud "chirp" every time it transitioned from ICE to EV. At first, the dealer couldn't "replicate the issue" so I had to go for a drive with the tech. Once I demonstrated the issue and specifically asked them to check the heat exchanger valve I was able to get it replaced under warranty.

No more chirp. Milage has also improved since having it replaced. That could be unrelated but I was averaging 18-19 before and have since been getting 20-22.

I can DM you a copy of the report with all the notes if that would be helpful to show your dealer.

Please do! DM me!!

 

[BobbyG]

Little hard to tell from your video but I second HammaMan.

I have a 2022 Lariat that was making a very loud "chirp" every time it transitioned from ICE to EV. At first, the dealer couldn't "replicate the issue" so I had to go for a drive with the tech. Once I demonstrated the issue and specifically asked them to check the heat exchanger valve I was able to get it replaced under warranty.

No more chirp. Milage has also improved since having it replaced. That could be unrelated but I was averaging 18-19 before and have since been getting 20-22.

I can DM you a copy of the report with all the notes if that would be helpful to show your dealer.

Could I trouble you to dm the report? Have exact same issue 21 powerboost.

 

[WA_502A]

Could I trouble you to dm the report? Have exact same issue 21 powerboost.

DM sent.

 

[WA_502A]

Here it is for anyone else that may be curious.

 

[Wangeltmg]

My dealership is saying it is not covered under warranty and will take 1k to replace it. I am pissed on how to resolve this. I also have extended warranty. The dealership says exhaust parts are not under warranty.

 

[backcountryplatinum]

Not true

 

[Snakebitten]

Dealerships have become a dang adversary.

 

[DANNER]

I've been hearing this chirp from my PB for quite a while. I took it in to the shop once for regular service and asked them to look at it, but they couldn't reproduce it. Finally realized it occurred consistently when the ICE engine shut off even when stationary (and sometimes when the ICE turns on). Brought the vehicle back in since I could constantly reproduce it, and they narrowed it down to a valve in the exhaust heat exchanger (Part No PL3Z5A212B).

However, dealership is also saying it's not covered by drivetrain warranty nor the bumper to bumper extended warranty I have. The part itself is $595.01 and $930.00 for install and diagnostic fee.

I guess I can call Ford customer service and see what they say. Any ideas on what else I can do here?

EDIT: Seeing WA_502A's invoice has a slightly different part number (They have "B" at the end and his has "C"). Wonder if they're ran the wrong number. Talking to Ford customer service now. But will need to call the dealership back to confirm they've got the right number.

 

[Fox146]

I've been hearing this chirp from my PB for quite a while. I took it in to the shop once for regular service and asked them to look at it, but they couldn't reproduce it. Finally realized it occurred consistently when the ICE engine shut off even when stationary (and sometimes when the ICE turns on). Brought the vehicle back in since I could constantly reproduce it, and they narrowed it down to a valve in the exhaust heat exchanger (Part No PL3Z5A212B).

However, dealership is also saying it's not covered by drivetrain warranty nor the bumper to bumper extended warranty I have. The part itself is $595.01 and $930.00 for install and diagnostic fee.

I guess I can call Ford customer service and see what they say. Any ideas on what else I can do here?

EDIT: Seeing WA_502A's invoice has a slightly different part number (They have "B" at the end and his has "C"). Wonder if they're ran the wrong number. Talking to Ford customer service now. But will need to call the dealership back to confirm they've got the right number.

If you have an ESP (bumper to bumper type) it should be covered. Not sure which one you have but maybe have a look through

 

[Snakebitten]

There's also a brand new CSP regarding the Exhaust Heat exchanger and Ford is warranting it now for 15 years/150,000 miles for a 1 time only replacement.

Admittedly it's not specifically for the noisy valve, but rather a malfunctioning valve. But maybe your noisy valve is an impending failure?

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