We all know how important regular oil changes are to your engine, but sometimes we sail close to the wind and let our engines run a little longer than the manufacturer’s service manual or dashboard gauges recommend . The Ford Ecoboost engine is the successor to the Duratec and has proven to be a robust and reliable engine.
The 3.5-liter turbocharged engine was first used by Ford in 2010 for the Taurus SHO and Flex, in 2011 for the F-150, in 2016 they introduced the second-generation version for the Platinum Edition and Explorer Sport and in 2018. for the Expedition. The F-150 pickup truck is by far the most popular model in which this engine can be found. Lincoln also used this engine in its Navigator, MKS and MKC.
However, there is a problem that is causing catastrophic engine and turbo failure despite Ford owners changing the oil according to Ford’s Intelligent Oil Life Management (IOLM) system recommendations . The system is designed to notify owners when it’s time for an oil change, but due to some inherent design flaw, the notifications are delayed.
Ford Tech Expert Brian from the YouTube channel fordtechmakuloco recently posted a video explaining the problem in detail. In the video, he explains that he’s been working on a lot of engines recently, many of which have to do with Ford engineering issues. He mentions a Ford Fusion that broke at 63,000 miles and a 5.0L failure at 175,000 miles.
What is the underlying problem and what is causing it?
Brian has over a decade of experience working with Ecoboost engines and his channel is a rich source of information on all things related to your Ecoboost engine. In the video, he shows a couple of stripped down engines and turbos to delve deeper into this common problem faced by Ecoboost engines, especially the 3.5 liter versions. It also clarifies that these engines are meant to run up to 300,000 miles before anything significant happens and that the owners of these engines performed regular oil changes according to the IOLM system.
Part of this problem is that there is generally a lot of stress and wear on the internal components from all the dirt build-up. Ford is aware of this problem and created a new motor oil with the SM+ SP specification. The engine in the video had done 2,24,000 miles when it failed, despite the vehicle’s owner changing the oil regularly as recommended by the gauge on the instrument panel.
This is a scary thought, as most trust the manufacturer’s warning to be the final word on when to change our oil. Another reason that caused the failure was clogging of the turbo oil filter screens with debris and soot. A turbo’s oil filter screen is designed to prevent fine soot particles from flowing through. There is usually a film of motor oil, which helps with lubrication and temperature control.
In the video, he already has both turbos already removed, one of which was stock and the other a replacement for the passenger side. He also shows us the extent of oil screen clogging and explained how most service technicians do not change them during routine maintenance, due to lack of experience or general laziness. The turbo that was replaced at one point still had the old oil screen, which caused the replacement to fail on the road as well.
The clogged oil filter screen causes the turbo oil to sputter, which at 185,000 RPM can be disastrous. The stock turbo had never been swapped and had much more extensive damage, with the compressor fan basically grounded from metal to metal contact. While there is some radial play in the compressor fans of turbos, even when new, it was taken to a whole new level of radial misalignment.
The damage from this caused the turbo to pour oil out the exhaust, draining the oil from the engine. The engine lost about four quarts of oil, leaving it running with two, and eventually failed, after internal parts began to fail one after the other.
This also meant that the thin screens of the Variable Cam Timing (VCT) became clogged with a mixture of dirt and metal particles from the engine’s self-destruction. This deadly combination of easily avoidable factors caused this Ecoboost 3.5 engine to fail at the owner, resulting in a very expensive engine replacement.
How to save yourself from a similar situation with your Ecoboost engine?
First off, don’t just rely on the gauge cluster for oil changes, Brian recommends changing the engine oil and oil filter on an Ecoboost engine every 5000 miles. It also strictly recommends 5W-30 semi-synthetic or synthetic oil with an API specification of SM+. API stands for American Petroleum Institute, and this grade can be found on the back of most motor oil containers.
Another solid piece of advice from Brian is that whenever you go in for any kind of turbo maintenance, insist that the oil filter screens be changed as well. Some common problems, the turbos of these engines are the coolant installation tents that fail and leak coolant, or the manifold sometimes breaks its studs, causing exhaust leaks. While all of these problems are bad in themselves, this gives you the opportunity to avoid a much bigger problem in the future.
Another maintenance recommendation from Brian for older engines, from 2011 to 2016, is to change the stock oil pump to a newer Melling M390 High Volume. Ideally, this change should be done at the 150,000 mile mark, but it can also be done any time any major work is done on the timing kit. This pump is designed with 20 percent more volume for older engines, but features a higher PSI setting.
However, they also include a standard 85 PSI spring in the box, which can be changed. Many technicians don’t want the hassle of getting to the pump, as Ford officially recommends removing the oil pan and front axle to replace the old pump. Brian has come up with a hassle-free method of replacing the pump without removing the oil sump, which he details in another video. In the video, he also shows you how to properly twist the replacement spring.
Although these issues have been reported, it is important to note that they may not affect all vehicles equipped with a 3.5 liter Ecoboost engine. Regular maintenance and prompt resolution of any potential problems can help mitigate these issues. Many long-time Ecoboost owners swear by their engines, claiming they’ll even make it to 400,000 miles before major problems start to crop up.
We recommend that you consult a qualified specialist or your nearest Ford dealer for a thorough diagnosis before and proper repair of any engine-related problems. By staying proactive, properly informed and ensuring regular maintenance, you can help extend the performance and longevity of your engine.
