Powerboost Cavitating Noise on Cold Start

[Snakebitten]

Hey guys

I posted a video of that same sound last winter. All I could get out of the dealer is “ford is working on it”. That was 8 months ago. I fully agree it seems like a pump struggling which makes me think It’s for the coolant lines that draw heat from the exhaust and go around the battery (to warm it). Explains why it goes away as soon as it warms up and why it only does it extreme cold as the coolant becomes Thicker.
My question is why wouldn’t they have caught this In cold weather testing. To my knowledge all vehicles go through the freezer test where they shove them in a freezer for hours then fire them up and beat on them. I know GM has a facility in Canada where they do that.

I could be wrong, but when I look at the coolant loop that uses the exhaust heat exchanger, it is not part of the Hybrid coolant loop that involves the battery. Unless my eyes deceive me.

Instead, the exhaust heat exchanger is almost directly plumbed to the heater core and appears to be Ford's way of quickly getting heated coolant for the ICE/Transmission/HVAC side of things.

I suppose it's possible that somewhere in the diagram there's an equalizer valve that connects both coolant loops, but it's not something that sticks out enough for me to spot it.

The Hybrid coolant loop also has something unique to it and that is the ability to use refrigerant to remove heat from the Hybrid components. So on the surface, the ICE coolant loop has unique ways to introduce heat quickly, while the Electric coolant loop has unique ways of extracting heat.

As for testing the Powerboost in extreme temperatures, I'm certain Ford did. Most trucks are not experiencing these anomalies.

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[Snakebitten]

Just For Informational purposes, I have included the Hybrid/electronic coolant loop.
Note that it's high temperature limit is 131F

That's why it makes sense to me that it doesn't need any help from the ICE coolant loop or the exhaust heat exchanger. 131F is considered HOT in the Hybrid coolant loop. In the ICE coolant loop 131F isn't considered even warm up yet.

 

[1985ns]

Wow fantastic information! Just hope whatever this noise is, isn’t something that over time has caused long term damage (especially after the warranty is up) ?

 

[Snakebitten]

Wow fantastic information! Just hope whatever this noise is, isn’t something that over time has caused long term damage (especially after the warranty is up) ?

I'm looking forward to hearing from you fellas that have the noise and get the fix.
Again, I wish I could be under one of those trucks while it's making the noise just to see if it's coming from within the bell housing, or somewhere completely external to the transmission. As LOUD as it is, there can be no mistaking where it is originating.

Worth getting dirty and changing clothes just to get it identified.

 

[dave91gt]

Ford replaced the transmission and torque converter in my 21 5.0 truck. After three attempts at replicating it, I finally had a cold snap where I had the dealer park it on a lift (elevated) overnight. I asked them to stand under the truck and remote start it. Next thing I know the service manager said Ford was expediting me a trans and converter as he (engineer) heard it loud and clear on video. This was at 6,000 ish miles. I’m waiting on cold weather to confirm it’s fixed (although my 4” MBRP exhaust now dominates the cold start noises). the new trans shifts fine but does whine a bit louder than the original. And my cold start was not as loud as the OP. But could hear it across my work parking lot on a cold day with remote start.

 

[Gros Ventre]

The diagram is for a 2022... does it apply to the 2021s?

 

[Snakebitten]

I had a 2021 Powerboost first, and purchased the service manual for it. I then swapped to my special order 2022 when it finally arrived and then purchased the service manual for its VIN.

While I am sure that there was some "evolution" hidden in there somewhere, I think it's almost entirely software.

Nothing design related that has stuck out to me. I do know my driveshaft was a shiny silver aluminum on the 2021, but is black on the 2022. But that might be the difference between 157" VS 145"?

I think it's safe to assume the cooling loops haven't changed, but I could post the 2021 diagrams if anyone wants me to.

 

[Ford Motor Company]

So, I’m brand new here and have just spent the past few hours researching this issue as, you guessed it, I have a Powerboost making the same noise on cold start (only around 36F). I just bought this truck a week ago and it only has 10k miles… So I’m now a little nervous about what I’ve gotten myself into.

In my research, I’ve read of three claimed fixes for this issue:
1) Trans fluid top up
2) Transmisson replacement…. Yikes
3) An electronic pump replacement (over on F150Forum)

Seems there’s still no clear cut answer as to what’s causing this racket, which is just insane to me. How has this not been identified by Ford yet? Doesn’t seem like an uncommon issue.

Now I’ve only heard it twice on my truck. Once was just this evening and, after I shifted it from park into drive, it went away. And driving it thereafter was completely fine which seems to be the consistent theme for all trucks with this problem.

My plan is to try to get it into my local Ford store to have them investigate but that doesn’t seem like a sure shot way to find resolution. Are there any recommendations on the approach I should take with the dealership to help them understand what’s going on, aside from taking a video of the underbelly chaos?

Thanks all, in advance, for any help here.

Hi there! Would you send us a private message with your VIN and dealership name and location? I’d like to look into this concern on my end.

 

[Ford Motor Company]

Glad I'm not the only one who has this issue... Guess it's what we get for getting a first-year model of something

Hi there! I can take a look into this noise concern for you. Please send us a private message with your VIN and dealership information.

 

[AndrewMC]

Hi there! I can take a look into this noise concern for you. Please send us a private message with your VIN and dealership information.

Waffle waffle have yet to hear about anyone getting anything meaningful out of these VIN requests. Just a bot looking for key words

 

[AndrewMC]

Just For Informational purposes, I have included the Hybrid/electronic coolant loop.
Note that it's high temperature limit is 131F

That's why it makes sense to me that it doesn't need any help from the ICE coolant loop or the exhaust heat exchanger. 131F is considered HOT in the Hybrid coolant loop. In the ICE coolant loop 131F isn't considered even warm up yet.

Very interesting they can both heat and cool the battery as required. I'm hopeful this speak to longevity of the HV battery over the years

 

[Porpoise Hork]

Tells me the aux pump is probably starving for fluid. Maybe try putting some 2X4's under the lower end wheels to bring it to level and then see what it does.

I have the PDF of the fluid check procedure on my computer at home. It's fairly easy but does require the transmission to be at operating temp. Oh and the dipstick plug is an ABSOLUTE PIA to break loose.

I'll post it up later this evening.

 

[Porpoise Hork]

Forgot I had it on my work computer as well.

If I remember correctly, there are two versions of the dipstick plug one with numbers and one with letters.

 

[Porpoise Hork]

I'm fairly sure it will be the same just depends on if ours uses the number stick or letter stick. I think the letter version was when Ford first released this transmission but then updated it in 2019 or 2020 with the numbered stick..


Some have A,B,C. Some have A, B only. Still other 10R80's have numbers.

Explained at time 38:40 on this video.

 

[Porpoise Hork]

Not sure if they changed it but here's the three dipstick versions as he describes in the video. They are all from 2020. What's messed up is my 20 Ranger had the numbered stick but others produced around the same time had the lettered version sticks. Wish Ford would get it straight.

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