2019 Ford F-150

The contact owns a 2019 Ford F-150. The contact stated that after starting the vehicle, there was an abnormal sound coming from the engine, with the check engine warning light illuminated. The local dealer was contacted; however, the vehicle was not diagnosed or repaired. The contact was informed that the VIN was not under recall. The manufacturer was notified of the failure. The approximate failure mileage was 59,600.

Vehicle Information: •Make: Ford •Model: F-150 •Year: 2019 •VIN: [XXX] Complaint Summary: Cam Phaser Defect — Safety Risk and Manufacturer Negligence 1. Component/System Failure This complaint involves a mechanical failure of the cam phaser system (part of the variable valve timing system) in the 3.5L EcoBoost engine of the above-referenced vehicle. Specifically, the locking pin within the cam phasers fails to engage properly, resulting in a loud knocking or rattling noise on cold start. This condition is a known defect documented in Ford TSB 19-2208 and subject to Customer Satisfaction Program (CSP) 21N03, which extended coverage for cam phaser repair. However, no official safety recall has been issued, despite widespread evidence of failure. The defective parts are still installed in the vehicle and are available for inspection upon request. 2. Risk to Safety This defect compromises driver and public safety and constitutes a violation of 49 U.S.C. § 30101 and 49 U.S.C. § 30118, which obligate manufacturers to notify NHTSA and owners when a defect poses an unreasonable risk to motor vehicle safety. Specifically: •Failure of cam phasers leads to improper valve timing, risking engine hesitation, loss of power, or stall conditions. •These symptoms can occur during acceleration, highway driving, or merging, creating conditions that significantly increase the risk of collision or engine failure while in motion. The defect may also cause internal engine damage over time, raising the risk of mechanical breakdown in traffic. 3.Confirmation of the Problem This issue has been confirmed by a certified Ford dealership and an independent ASE-certified mechanic. Both diagnosed the startup noise as a cam phaser locking failure, consistent with widespread reports from other Ford 3.5L EcoBoost owners. Neither party could provide a fix without significant out-of-pocket cost, despite Ford’s knowledge of the issue and internal bulletins acknowledging the issu INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)

I drive a 2019 Ford F-150 with the 3.5L engine and 10 speed transmission. I have received a warning for low fuel pressure, trouble starting, and the truck has cut off once after turning over. It never fails to crank, however, it may take 5 or so seconds of cranking to get it to start. I have had the check engine light come on one time over the last couple of months of the issues starting; the code it showed was a P00C6. I have not brought the vehicle in for service as it just started a couple months ago when it got hot outside and there was a recent recall that did not include this VIN but matches the issue exactly. The warning states to not drive the vehicle and to get it towed if fuel is not low. The recall states there is not a current fix for the issue and I need my vehicle. This is a daily problem, mostly after the vehicle sits for a couple of hours. I am also having an issue with the cam phaser rattle upon startup and rattling while driving. I have noticed some power reduction and it has progressively gotten worse over time. I am at 135,000 miles currently and have experienced this issue for the last 50,000 miles or so.

I purchased this truck about a year ago. After two oil changes, the cam phasers began to rattle on startup. It has the 3.5l Ecoboost engine. This is a known problem and there have been tsb's but they come and go during short windows. The cam phasers were finally updated in 2021 but some people have paid thousands in and out of warranty, some multiple times before the issue is fixed. Ford says they are just a noise and do not cause any issues but the resale is directly effected whether private party or trade in (repair typically costs between $4-7500). Mine started making noise at 89,000 miles. Some people go years with the engine rattling and others have check engine lights and engine issues a shirt time after it begins. Ford knows it is a problem and the customer service sometimes will assist with the cost and other times they tell people to file a complaint here to finally get a recall going. The repair is in depth and typically requires the removal of the cab from the frame, making it likely that everything won't be reassembled correctly.

At 101,000 miles, the engine lost power, check engine light came on, and service transmission light came on. This happened while pulling a trailer up a mountain, slowing the truck rapidly, and becoming a hazard to surrounding interstate traffic. The dealer diagnosed the problem as the timing chain, and replaced it and all related components at a cost of $4500. They tell me that this is a problem with that year truck and engine.

The contact owns a 2019 Ford F-150. The contact stated while driving 5 MPH from a complete stop on a main road, the vehicle lost motive power. There was no warning light illuminated. The vehicle was able to restart, and the contact continued driving. The vehicle was taken to a local dealer to be diagnosed, but the cause of the failure could not be determined. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 30,000.

The contact owns a 2019 Ford F-150. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the catalytic converter had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The approximate failure mileage was 94,584.

The contact owns a 2019 Ford F-150. The contact stated that the vehicle made an abnormal loud rattling sound on cold starts. The contact related the failure to Ford Campaign Number: 21N03. The dealer was notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.

The contact owns a 2019 Ford F-150. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. In addition, the contact stated that when the vehicle was started, the contact noticed an abnormal rattling sound. The contact stated that the Ford Mobile App indicated an engine misfire. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The vehicle was scheduled for diagnostic testing within the next several days. The manufacturer was made aware of the failure and a case was filed. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 110,000.

The contact owns a 2019 Ford F-150. The contact stated while the vehicle was parked, the contact inspected the vehicle and noticed that the oil level was low. The contact topped off the oil. The contact stated that the following day, the oil level was inspected, and the contact noticed that the oil level was low again. No warning light was illuminated. In addition, the contact stated that there was no visible indication of an oil leak. The dealer was made aware of the failure. The manufacturer was made aware of the failure. The contact was advised to take the vehicle to the dealer for a diagnostic test. The manufacturer requested an oil consumption test be performed. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 90,000. The VIN was unavailable.