I need advice. We operate a garage, did an oil change on a 2007 F150 with a 5.4L, with 70,000 km. A few days later, began to make noise. Owner took it to the dealer, the dealer told him it needed an upper engine rebuild, $6,000. A technician at the dealership said the oil filter came apart and caused the engine damage. Scored cam guides and cam shaft damage. Installed OEM recommended, Pennzoil 5w20, and Pennzoil PZ42, Purolator manufactured. No loss of oil, proper quantity of oil installed. Sent the filter to Purolator for testing, came back 100% within specifications, no missing parts, gaskets present intact. Any suggestions as to what would cause this damage?

 

The only thing I can think of in the filter that could possibly cause that kind of damage would be a defective or "stuck" anti-drain back valve causing oil starvation. That's why I never use anything but motorcraft oil filters, if one of those go bad at least the dealer won't have the excuse of the use of an aftermarket filter.

 

Thank you for the reply. This was the first time we did an oil change on this vehicle. We do not know the service history, was it service with the proper viscosity oil (5w20) / interval? Was there sludge in the engine, did the high detergent oil loosen the sludge, causing a cam phaser, which is hydrolically operated and lubricated to fail? Was the damage masked by a heavier oil, took a couple of days for the heavier oil film to wear off, revealing the knock. Known cam phaser problems, can occur at any time.

We did our checks and double checks, RPM check to verify the filter and detect any oil pump problems. The vehicle left with everything operating normally. The anti-drain back valve only keeps the system primed, if it fails, the filter becomes a by-pass filter, there should be no starvation. The Filter was sent to Purolator and found to be 100% to OEM Specifications.

The Mechanic at the dealer said the filter came apart and the gasket was all over the engine. The visual inspection of the filter showed everything present and intact. Is there a source of gasket / rubber insid a 5.4L engine?

 

Exactly!...........

 

What kind of oil filter came off the engine I wonder?

 

Unfortunately, we would have no way of knowing what oil filter came off the vehicle. The PZ42 was the correct application for this vehicle. I made a typo in the title and incorrectly listed the engine size as a 5.5L, my mistake. It was a 5.4L.

The mechanic at the ford dealer told the owner the oil filter caused the engine failure. The filter was tested and found to be 100%. What internal part could have caused rubber inside the engine?

 

The failure of a previously installed filter? As you say, the maintenance and operational history are unknown to you.

 

That was my thought.

Purolator is a good brand .... I was wondering if maybe the previous filter was a sub par one that maybe was already coming apart even as you were changing the oil / filter? No way of knowing?

Did Ford Garage save any rubber scraps they found? Do they match that used by Purolator?

 

Purolator does not make Penzoil filters, Honeywell does. Honeywell also makes Fram. Most likely some glue used to bond the paper media to the cardboard end caps came loose and got lodged in the oil passage leading to the cylinder head. I have seen it a few times and all the engines had a Fram or other Honeywell filter on. I don't know how you sent the filter to Purolator to get tested when they didn't make it. For proof cut open a Penzoil and a Fram filter and compare them. Here and here is some more info on filters. If the engine ran fine before the oil change then the filter came apart or someone forgot to put oil in it before it was started. There is nothing rubber in the engine between the oil pump and heads. The only rubber is the gaskets on the chain tensioners but even if they failed the heads would still have enough oil pressure to prevent any damage because the tensioners are fed through a orifice that reduces the pressure to them.

 

If so ... I wonder why it was sent to Purolator and tested ?

Did a search, looks like at one time, in some regions, what you say is correct. However, there is evidence on the net that they are now built by Purolator as are the "Super Tec" brand?

Anyway, Motorcraft on my 5.4 and 4.6s.

 

OK I did some more research and am getting conflicting info. Every Pennzoil filter I have seen looks just like a Fram. I guess the OP needs to post some pics of the filter so we can be sure.

 

100% sure the Pennzoil branded filter was manufactured by Purolator. I have the report. Gasket was still intact.