Powerboost Rattle - Cam Phasers When Switching from Electric to Gas/Hybrid Mode?

[Jerome10]

There has been some discussion about a heat shield-type rattle that I've had since getting my truck. Link here:

However, I don't really feel my question fits there so asking a new question....

Is it possible that you hear the cam phaser rattle when the truck fires up and switches from electric to gas driving? Or if you had failing cam phasers would this only be heard the very first time the engine starts in the AM or the very first time it fires up when you first begin driving? The rest of the trip, no cam phaser noise is heard?

The reason I am asking is that the noise my truck makes seems like 1) it sounds quite similar to me as the youtube videos showing the cam phaser cold start noise. That metallic, marbles-type rattle. 2) it seems to make the noise loudest and most consistently after I've been in electric mode and then the engine fires up. Also the first cold fire up in the AM also very noticeable. If the engine has been running or idling and I accelerate to the same RPM where I hear the noise often I will not hear the noise or if I do, it is much more muted.

I pay attention to gauges to maximize electric drive. There are parts of my routine where I can probably cruise upwards of 2 minutes constant in electric mode. And so I'm wondering if this time with the engine off is allowing the oil to drain out of the phasers, then the engine fires up, and I get the bucket of marbles sound?

However, I can also seem to make the noise occur with the engine running, truck in park, and just revving the engine to the target RPM (around 1500-1800). It won't ALWAYS do it but often will. If my understanding of cam phasers is correct, this wouldn't be cam phasers, correct? The engine has full oil pressure and therefore the cam phasers would be working properly?

And generally, where would you be most likely to hear a cam phaser noise? Front top of engine?

I'm just trying to do a little pinpointing and dial in exactly under what conditions I hear this marbles-like sound. Had it at the dealer ages ago and told it was the wastegate rattle... but I'm extremely skeptical this is wastegate noise. Now wondering if it might be my cam phasers...

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[dafish]

This is NOT gospel, but:

Cam phasers were much improved by I think 2021, and most certainly by the time of your '23.

The noise is very much top-front (right where they are), and when at cold startup. Once running and warmed up I personally didn't hear it. It was very much a startup sound

I would lean towards something else., but I've a total experience of one, so....

 

[Jerome10]

OK, I think this may make some sense based on a little more info gathering. Cold (as in never running for hours) and it shows up.

 

[cligon3]

There has been some discussion about a heat shield-type rattle that I've had since getting my truck. Link here:

However, I don't really feel my question fits there so asking a new question....

Is it possible that you hear the cam phaser rattle when the truck fires up and switches from electric to gas driving? Or if you had failing cam phasers would this only be heard the very first time the engine starts in the AM or the very first time it fires up when you first begin driving? The rest of the trip, no cam phaser noise is heard?

The reason I am asking is that the noise my truck makes seems like 1) it sounds quite similar to me as the youtube videos showing the cam phaser cold start noise. That metallic, marbles-type rattle. 2) it seems to make the noise loudest and most consistently after I've been in electric mode and then the engine fires up. Also the first cold fire up in the AM also very noticeable. If the engine has been running or idling and I accelerate to the same RPM where I hear the noise often I will not hear the noise or if I do, it is much more muted.

I pay attention to gauges to maximize electric drive. There are parts of my routine where I can probably cruise upwards of 2 minutes constant in electric mode. And so I'm wondering if this time with the engine off is allowing the oil to drain out of the phasers, then the engine fires up, and I get the bucket of marbles sound?

However, I can also seem to make the noise occur with the engine running, truck in park, and just revving the engine to the target RPM (around 1500-1800). It won't ALWAYS do it but often will. If my understanding of cam phasers is correct, this wouldn't be cam phasers, correct? The engine has full oil pressure and therefore the cam phasers would be working properly?

And generally, where would you be most likely to hear a cam phaser noise? Front top of engine?

I'm just trying to do a little pinpointing and dial in exactly under what conditions I hear this marbles-like sound. Had it at the dealer ages ago and told it was the wastegate rattle... but I'm extremely skeptical this is wastegate noise. Now wondering if it might be my cam phasers...

@Jerome10, did you ever get to the bottom of your noise? You've described what I'm dealing with to a T, also a 2023 Poweboost. I've had two shops tell me it was the wastgate and I've added springs, but those didn't help. What does seem to help is when I rev the engine in park a few times to get the rattle noise and then it slowly goes away. Its then gone next time I start from cold. The wastegate is actuating when it revs so I assume that is the culprit. It also seems to have a little play when I mess with it cold.

 

[Jerome10]

@Jerome10, did you ever get to the bottom of your noise? You've described what I'm dealing with to a T, also a 2023 Poweboost. I've had two shops tell me it was the wastgate and I've added springs, but those didn't help. What does seem to help is when I rev the engine in park a few times to get the rattle noise and then it slowly goes away. Its then gone next time I start from cold. The wastegate is actuating when it revs so I assume that is the culprit. It also seems to have a little play when I mess with it cold.

Unfortunately I have not solved it. I took the truck in about 2 weeks ago, but it was very warm outside and it almost completely disappears when above about 65F. Of course the one day I have it in, it doesn't make the noise, and I even stuck around to demonstrate. I'm almost positive it is NOT the wastegates. The noise is somewhere under the rear passenger seat area.

I am nearly certain it is either the heat exchanger or the resonator. I actually think it might slowly be getting louder. I hear it basically every time I pull away from a stoplight or stop sign if under that 65F temperature. Drives me bonkers. Sounds like marbles or a junky old clunker.

If you search around this forum and the internet, you'll find a decent bit of discussion on the resonator and/or exchanger being the culprit. Some owners have removed their resonators, but the Powerboost I guess the resonator and heat exchanger are 1 single part number, so you can't just remove the resonator portion. Some folks I think have said their dealer replaced their heat exchanger and the noise came back. I want to also say (don't hold me to this one...been awhile since I was searching) that Maverick hybrid owners have had similar rattle complaints.

At this point, being summer, I plan to just take it back in this fall when the noise returns. I go off warranty at the end of May 2026 so hopefully I can get them to take care of it.

I think the current part number for the heat exchanger + resonator is PL3Z-5A212-C. One parts website shows that this part number supersedes 4 older part numbers, so I think this is the 5th revision of the part. Makes me wonder if perhaps 2023 has an older part number more prone to rattles. The part is about $500 unfortunately (not including labor).

But I think if you hit google with searches like "Powerboost heat exchanger rattle" or "F150 resonator rattle" you'll get some hits.

 

[cligon3]

DmAC has a video that sounds just like what I have, coming more from the drivers side. It was solved by replacing the cat.

https://www.f150gen14.com/forum/threads/clanking-rattling-when-revving-or-starting-engine.7093/

 

[Jerome10]

DmAC has a video that sounds just like what I have, coming more from the drivers side. It was solved by replacing the cat.

https://www.f150gen14.com/forum/threads/clanking-rattling-when-revving-or-starting-engine.7093/

Yup, I've posted a bit in that thread as well Hopefully it isn't the cats.

 

[dadrew]

I have been wondering about this same noise for some time.....I thought it was what looks like to me the heat shield that covers the muffler

just one more thing that id like fixed on this truck along with the loss of pedal and acceleration from time to time

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