Ford F-150 knocking problems

Filed Nov 5, 2026 · Engine · KY

I own a 2018 Ford truck with 77,000 miles. My truck has just experienced the widely recognized cam phaser failure—a known design defect that can cause a catastrophic engine failure to occur. Because this is a known manufacturing defect that Ford addressed with updated parts, TSB 23-2143 (or TSB 21-2119): These are the official internal Technical Service Bulletins that explicitly instruct Ford technicians on how to diagnose and repair the "cold start ticking/tapping or rattle type noise" on 2017–2020 F-150s with the 3.5L EcoBoost engine. It confirms the root cause is a worn Variable Cam Timing (VCT) unit and outlines the procedure to replace all four phasers. [1, 2] Customer Satisfaction Program 21N03: While the prorated financial assistance under this program expired in January 2023, the document itself remains critical. It serves as corporate documentation where Ford explicitly acknowledges a manufacturing/design flaw in the original cam phasers. Ford refuses to replace or reimburse this repair for any vehicle that is out of warranty. This is a known safety issue acknowledged by Ford and it should be addressed as a safety concern and recalled.

Filed Oct 13, 2026 · Engine · 64,900 miles · FL

The contact owns a 2021 Ford F-150. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated, and a alert was received through the mobile application. The vehicle was taken to a dealer, where a diagnostic inspection revealed that the knock sensor failed and required replacement. The dealer informed the contact that water intrusion on the intake manifold caused the knock sensor failure. The vehicle was scheduled for repair at the dealer. The contact attributed the failure to the factory omission of the engine cover and the cowl design directly above the engine compartment, which allowed water to collect on the manifold. The manufacturer was notified via telephone, and a case was filed. The failure mileage was approximately 64,900.

Filed Oct 3, 2026 · Suspension · TX

In my year 2000 Ford 150. I had the passenger window down and noticed it was sprinkling. I went outside to put the window up and when I closed the door, the back window of the truck literally smashed to pieces. I was told it was because of heat. I took pictures of everything. I am writing this as a recall so no one else will experience this or possibly get hurt. Also, the motor blew out at in the range of 180,000 miles. I was told the rods were knocking so hard.

Filed Sep 24, 2026 · Electrical, Engine · VA

Re: Recurring Knock Sensor Failure — 2024 Ford F-150 STX (2.7L) I am writing to document a recurring mechanical issue with my 2024 Ford F-150 STX, 2.7L, currently at approximately 30,900 miles, purchased new. First Incident (late XXX): While driving, the check engine light illuminated, indicating a knock sensor fault. I brought the vehicle to Ted Britt Ford in [XXX], where it remained for five days for sensor replacement. I requested a loaner vehicle, which the dealership stated was unavailable, requiring me to rent a replacement vehicle at my own expense. Second Incident (XXX): Following a period of heavy rainfall, the check engine light returned with an identical knock sensor fault. The vehicle was again taken to the same dealership and held for five days for repair. When I again requested a loaner, I was informed one could not be provided because the vehicle was not originally purchased at that dealership. Rental Costs: Across both repairs, I have incurred rental vehicle expenses for a combined 10 days due to the dealership's lack of loaner availability. Suspected Root Cause: Based on the pattern of failures — particularly the correlation with heavy rain — I believe water may be intruding into the engine compartment through the hood cowl area and affecting the knock sensor. I have found numerous other reports from Ford F-150 owners describing similar symptoms, which suggests this may be a broader design or manufacturing issue rather than an isolated incident. Concerns: Given that this is a low-mileage, recently purchased vehicle experiencing the same failure twice within approximately three to four months, I am concerned this issue will recur once the vehicle is out of warranty, at which point repairs would no longer be covered. I believe this pattern warrants investigation, and potentially a recall, given the apparent frequency of similar complaints among other owners. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Sep 6, 2026 · Engine, Transmission · AK

We purchased this 2014 Ford F-150 SuperCrew (3.5L EcoBoost) used on Dec 31, 2022. Just two days after taking it home, the vehicle began experiencing sudden, violent, uncommanded downshifts from 6th to 1st gear at highway speeds. This occurred throughout our ownership. Because this was our family's only form of transportation, we had no choice but to continue driving it under these terrifying conditions, repeatedly navigating a lethal safety hazard with our three children in the vehicle until the powertrain suffered a catastrophic failure. This matches the exact defect investigated under the federal safety agency Campaign 24V444 / Recall 24S37 and expanded under Recall 26S45. On Dec 23, 2023, a final highway downshift forced the powertrain into 1st gear, creating immense kinetic stress and engine-braking that instantly shattered internal components and caused a severe engine knock. Less than a mile later, while trying to get our family home in life-threatening -40 degree Fairbanks winter weather with our three children inside, the engine completely blew, leaving us stranded. The Fairbanks Ford dealership initially stated that Ford would be liable for the consequential damages. However, it later backtracked, claiming that a local customer satisfaction program had "timed out" at the 150,000-mile threshold. A diagnostic certification from a local Nissan dealership has documented the failure. I was an original reporter aiding the push to reopen this failed software recall investigation, and Ford's corporate delays allowed this defect to destroy my engine before a real fix was issued. Due to this defect, our family has suffered extreme financial hardship: we spent $6,513.68 out of pocket for a 5-month Turo rental starting Christmas Day 2023; I was forced to leave my job due to a lack of transportation in a sub-zero climate; and I had to liquidate my retirement early. We have paid on time for 3 straight years on a broken vehicle and currently owe $19,633.44 on a financial ghost. Ford Motor Co

Filed Aug 27, 2026 · Engine · CA

Not sure if I can file an issue for this, but I wanted to let you know that a Ford Safety recall caused other issues after it was applied. In late July 2026, my son received a Ford safety recall notice (Recall #26S28) for his 2017 F 150 requiring a PCM software update. I brought the truck to Crown Motors in Redding on August 11th for the recall service. Before this appointment, the truck had no performance issues. Immediately after picking up the truck, a noticeable pinging sound occurred under acceleration. I returned the vehicle on August 12th, where Crown Motors confirmed the issue and advised spark plug replacement. This did not resolve the problem. I was also told that continued driving could damage the engine, so the truck remained at the dealership. Over the following days, Crown Motors worked with Ford engineering and repeatedly attempted software-related fixes. Crown staff informed me they believed the recall update caused the issue, and the first internal Ford team reportedly agreed. However, on August 25th, Ford’s second internal review determined the software update was not responsible and stated that all repair costs would fall on me—despite the clear timeline showing the problem began immediately after the recall service. Customer Service provided no assistance and refused to escalate my concern. As a result, my truck is currently non-operational, Crown Motors does not have a fix, and Ford will not cover repairs triggered only after Ford’s own safety recall. I believe the Spark Knock issue is an additional safety issue caused by the PCM recall update that was I was told could cause engine failure.

Filed Aug 27, 2026 · Engine, Fuel system · OH

While driving, my 2022 Ford F-150 equipped with the 2.7L EcoBoost experienced abnormal engine operation, a check-engine light, and reduced engine power. The unexpected reduction in available engine power created a safety concern because loss of acceleration or propulsion can be dangerous when merging, crossing traffic, passing, or traveling at highway speeds. The vehicle was inspected and diagnosed by an authorized Ford dealership. The PCM stored DTC P0332, Knock/Combustion Vibration Sensor “B” Circuit Low. The dealer performed Ford Pinpoint Test DG. Testing reportedly found no open circuit, short to ground, short to voltage, or intermittent circuit fault. The dealer determined that the knock-sensor assembly required replacement.The repair involves replacement of Ford knock-sensor assembly FT4Z-12A699-E, which contains both knock sensors. Access to the assembly requires extensive disassembly of engine fuel and cooling-system components. Ford’s service procedure includes removal of both direct-injection fuel rails, draining the cooling system, removal of the coolant pump, and removal of the coolant outlet connector.I am concerned about the possibility of coolant leakage or contamination affecting the knock-sensor assembly because of its location in relation to cooling-system components. I do not currently know whether coolant contamination caused this particular failure. I request that the federal safety agency investigate whether coolant leakage or contamination in this area contributes to premature knock-sensor failures on 2.7L EcoBoost engines. I have also identified another 2022 Ford F-150 with the 2.7L EcoBoost that was diagnosed by a Ford dealership with a similar knock-sensor circuit-low fault, P0327 also quoted replacement of the same FT4Z-12A699-E assembly. I request investigation knock-sensor failures on 2.7L EcoBoost F-150s, including Ford warranty/field data and whether coolant leakage or contamination contributes to failures capable of causing unexpected reduced engine powe

Filed Aug 11, 2026 · Brakes · 114,089 miles · TX

The contact owns a 2018 Ford F-150. The contact stated that while driving 55 MPH, the message "Brake Fluid Level Low" was displayed. The brake pedal was depressed and went to the floorboard. The contact stated that the brakes failed to work properly. The contact drove to Walmart and purchased brake fluid to add to the vehicle, but the failure persisted. The contact added more brake fluid, but the failure recurred, and the engine made a knocking sound with smoke coming from the exhaust pipe. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The contact related the failure to the federal safety agency Campaign Number: 22V150000 (Service Brakes, Hydraulic); however, the VIN was not included in the recall. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 114,089.

Filed Jul 9, 2026 · Engine · NC

I purchased my 2017 Ford F-150 Raptor in October 2017. On December 27, 2019, at 27,775 miles, the cam phasers were replaced under warranty using Ford part numbers beginning with HL3Z. In June 2026, at 74,665 miles — fewer than 47,000 miles after that repair — I began experiencing the same cam phaser symptoms (rattle/knock at cold start and idle) that led to the original repair. At no point was I notified by Ford or my dealer that the HL3Z parts used in my 2019 repair were known to have the same defect as the original phasers, despite Ford having since transitioned to an updated part (ML3Z) referenced in its own Customer Satisfaction Program documentation (CSP 21N03 and Supplements #1–4). I contacted Ford Customer Service in July 2026 requesting assistance with the recurrence and was told no help would be provided. I am concerned this failure can progress to loss of engine power or a more serious failure while driving, based on the known failure pattern of this component. The repair is labor- and parts-intensive, creating a significant cost burden for a defect Ford appears to have known was unresolved by the original repair parts. Reference documentation: SSM 48272, TSB 20-2191, TSB 20-2315, CSP 21B10, CSP 21N03 (and Supplements #1–4), TSB 23-2143.

Filed Jul 8, 2026 · Acceleration, Transmission · LA

On Thursday, XXX, at approximately 5:10 AM, I was driving my Ford F-150 XLT (VIN: [XXX]) eastbound on [XXX]. While exiting the elevated bridge at the intersection of [XXX] and [XXX] at 55 mph (6th gear), the vehicle experienced a sudden, uncommanded transmission downshift directly from 6th to 1st gear. This caused immediate extreme deceleration, engine over-speed, and locked the rear tires, causing tire slippage and an absolute loss of traction control on a high-speed highway. This severe event put my life and my wife's life in imminent danger of catastrophic injury. After safely pulling over, the Malfunction Indicator Light (Check Engine) and the Powertrain Fault Warning Light (wrench icon) illuminated. The electronic cluster froze and failed to display the gear position. Drive (D) mode was completely unresponsive. I managed to vacate the active roadway using Manual (M) mode. While driving in 4th gear in manual mode under extreme caution, a second violent, unintended downshift to 1st gear unexpectedly occurred, confirming the persistent, dangerous nature of this failure. Consequential mechanical damage includes severe transmission clunking noises during gear engagement and a constant internal metallic knocking sound from the engine block caused by the forced over-speed. This failure perfectly matches the technical failure mode described in the federal safety agency Safety Recall Campaign 26V237 (OSS to PCM signal loss). On XXX, at 11:10 AM, I personally visited Arceneaux Ford Inc. (Authorized Dealership in [XXX]) to report this safety defect, open a service case, and request a safe vehicle inspection and loaner. The dealership explicitly refused to open a case or take action, stating that "Ford Motor Company does not currently have an engineered solution for this problem," leaving me stranded with an unroadworthy, highly hazardous vehicle. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)