My '18 3.5l has been rattling really bad each morning on a cold startup. Before researching the issue I suspected either the timing chain tensioners or a valve problem. Upon doing some research, I found out about the Cam Phaser problem, specifically with the 3.5l Ecoboost. I think this is going to be a BIG issue for Ford. The current TSB for fixing it is to simply do a 're-programming' and hope the owner doesn't notice that it didn't fix the problem - or at least mask the problem until the warrantee is expired. I took my 18 3.5l SCREW in last week, just saying that it rattles on cold startup. I didn't want to prejudice the tech as to what I suspected the problem to be. They called me about a day later and said it was a known issue with the Cam Phaser and 'easily' fixed with a re-program. When I went to pick up the truck, they said it was in the back lot and the tech would bring it around. No big deal, but this is my second car from this dealer, and I have had them do multiple maintenance things over the years, and my vehicle is always in the front parking lot so I can get in, start it, and go. So the tech brings it around, I get in and go. The next morning I start it up and the rattle is worse. I'm not talking about a faint 'ticking' - it's a loud rattle that people say 'WHAT THE HECK IS THAT NOISE!' when the truck starts (even my wife noticed it)). I drove it for a couple of days because I didn't have time to take it back to the dealership. After the programming, the rattle is also noticeable during all warm startups. Prior I would only hear it on the first startup in the morning, but the rest of the day it was normal.

I took it back and they are now replacing the Cam Phasers. It appears to be a pretty major job. It took a day to get Ford to authorize the warranty repair. The service writer said they have 3 other F150s in the shop right now for the same problem.

 

My 17 is at the shop now getting the replacement. I had the check engine light, code p0012 i believe. The extended warranty company took 2 different tries to get approval (not the ford warranty). It has been at the shop for 2 week since they started the repair. They had to order parts, the mechanic working on it got covid and I am not sure what the hold up is now.

 

When I worked for FORD as a service writer, they had, IMO some dumb rules/guide lines. In your case the order probably was to do the re-program first, THEN if there was still a "ticking", they tear it down.

I didn't actually see any 3.5 with cam phaser noise, BUT the 5.4 was a totally different deal.

I seriously hope they fix your truck ASAP !!!!!!!

 

My daughter's 2018 truck did the same thing and the dealer in Savannah , Ga took it right in and did the tear down and repair immediately. She had her truck back in a few days. I read the repair ticket before agreeing to pick up the truck and according to their language, they did what needed to be done and she's had no issues since.

 

Did this fix your issue? They did all that and more on my 2019 3.5l eco boost and it still rattles and shutters. The dealership brought in an engineer and told them what needs to be done, yet the FORD ESP isn't wanting to authorize the repair, these issues started before the original warranty expired, yet they are trying to fixit under the ESP.

 

It did solve my issue, no more rattle as of yet. I do still need to get my leak fixed. It seems to have slowed down, not that it was ever very much. I just smell a burning oil smell every once in a while