2022 2.7 "Popcorn" Popping Noise Under Acceleration?

[slaw11]

Having the subject issue and wondering if anyone may have any insight or similar experience. Dealer has had truck for 2 weeks, cant diagnose, and are waiting on Ford hotline. 2022 2.7 Lariat with 34k miles.

Bit of backstory for context:

• Had knock sensor electrical fault error. Knock sensor replaced end of April 2025. Took care of issue.
• Put 100 miles on the truck with no issues, then the popping noise under acceleration presented itself.
• Dealer thought injectors and replaced bank 1 direct injectors, and the issue is still present.
• The popping (thinking backfiring?) is present at all speeds and directly correlated with accelerating
• Dealer has been very unresponsive, and I have a suspicion that maybe they reassembled the intake manifold incorrectly when replacing the knock sensor.
• This isn't a ticking or minor popping. It is very loud and present during acceleration. I will try to add a video to this thread when I go to check status later in the week
• Dealership also said truck is safe to drive for now, which I am refusing to do.

I attached the tech notes as well. Looking to the forum, as the dealer seems to be grapsing at straws. Appreciate any input in advance

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[mwheue]

I'm not a mechanic but, sounds like they left something in the intake that is now holding a valve open. I wouldn't drive it either.

 

[Okgearhead]

If it’s popping through the intake, it’s usually something mechanical, like a valve or a camshaft, if it’s popping through the exhaust, it’s usually electrical , like the ignition, plugs….

 

[slaw11]

Update. Ford hotline advised dealer to check injector seals in bank 2. Will update once I hear back.

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