For nearly 50 years, the Ford F-150 has been one of, if not the, best-selling new cars in the United States. According to Business Insider, more than 33 million F-Series trucks have been sold since 1977, the majority of which were F-150s. In such a rich and all-encompassing history, there have been many great F-150 engines. Think of the 300 cubic inch inline-six, the 5.8L 351 Windsor, the 3.5L EcoBoost V6, all of which are some of the best engines ever built for Ford trucks.
Some have even become mainstays of American infrastructure, while others have brought the F-Series into the 21st century. Not all Ford engines have the same opinion, however, as some are less reliable or more controversial than others. The ownership experience may vary, but some devices are closely associated with recurring problems and expensive repairs. Therefore, you should avoid the following Ford F-150 engines.
Read more: The 10 most reliable six-cylinder engines of all time
Ford 5.4L Triton V8
Close-up of the Ford F-150 XL 5.4 Triton engine badge. – DEBOSS GARAGE/YouTube
As Car Wizard put it, this engine is “my personal most hated engine on the planet.” He went a step further, calling the unit “absolute garbage” and warning owners who defended it that their trucks were still running and “just waiting.” He also claimed, “I’ve personally replaced 14 of them…about six or seven pandemics.” We also did our best to find the worst engine Ford has ever put in a truck, and you guessed it, it’s the 5.4L Triton.
When it comes to the most serious issues with the Triton, spark plug-related issues on early models are certainly at the top of the list. In addition to being difficult to remove without special tools (as Ford admitted in TSB 08-7-6), the luckiest drivers have even had plugs fly out of the sides of the cylinder head due to poor cylinder head design. Other common issues with Tritons include sludge buildup, timing system issues, fuel system module corrosion, and gasket and oil leaks.
Although Ford has never recalled any vehicles due to the Triton engine, it has made numerous announcements. The variable valve timing problem (often described as the “death rattle” by owners and technicians) is also associated with the 5.4L Triton. These appear to be largely related to oil pressure related cam phaser operation and sludge buildup.
Ford 3.5L EcoBoost V6 (previous generations)
A blue 2012 Ford F-150 parked in an urban environment. -Benedek/Getty Images
As a disclaimer, not all Ford 3.5-liter EcoBoost engines deserve inclusion on a “worst F-150 engines” list, but exceptions must be made for certain early versions. Specifically, pre-2015 EcoBoost V6 engines are associated with expensive timing chain issues, so they’re one of the worst years of Ford’s 3.5-liter EcoBoost you should avoid. Again, no recalls were issued, but Ford did issue procedures TSB 18-2305, TSB 15-0131, and TSB 21-2119, all of which are related to cold-start rattling, variable cam timing component wear, and noise conditions related to the timing chain or phaser 3.5 seconds ago.
In addition to timing chain issues, 2017 to 2020 models are also prone to cam phaser issues. Ford did issue Ford 21B10 service action, which directly addresses cam phaser noise complaints on 2017 through 2020 vehicles equipped with the Ford 3.5L EcoBoost GTDI V6. The program expands repair coverage and instructs dealers to reprogram the powertrain control module to mitigate cam phaser noise. Additionally, a separate Ford 21N03 Customer Satisfaction Program has been released to provide cam phaser replacement for vehicles that continue to experience problems after the update.
Other problems with early 3.5-liter EcoBoost engines included leaking coolant from the turbo coolant fittings, damaged exhaust manifolds and leaking vacuum pumps. Overall, the Ford 3.5-liter engine is far from the worst engine Ford has ever produced, but considering early iterations of this engine had serious problems that could cost thousands of dollars to fix, it had to be included.
Ford 4.2L Essex V6
A red Ford F-150 from the 2000s is parked in “Wild West Town.” – Nikonysta/Shutterstock
The Ford Essex V6 engine range is infamous for replacing the proven V8 engine with a relatively smaller but equally powerful V6 engine. However, when Flying Wrench ranked Ford F-150 engines from best to worst, they placed the 1997 to 2008 Ford 4.2L Essex V6 in the D (lowest) category, saying, “You know one day it’s going to let you down.” One of the 4.2L Essex V6’s major pain points has to do with its intake manifold gasket failure.
If you’re unlucky, you may experience coolant leaking into the cylinder, which can cause the cylinder to lock hydraulically or even bend the connecting rod. Ford did issue TSB 99-20-7, which addresses internal coolant leaks in 1995 to 1998 4.2-liter Essex engines caused by a failed lower intake manifold or front cover gasket. The advisory outlines revised shim designs and installation torque specifications to address this issue.
However, that didn’t stop the 4.2-liter V6 from suffering similar problems to the Ford V8. In addition to the intake gasket issues, the 4.2 also suffered from a leaking timing cover gasket and ignition issues. Ford discovered a timing cover issue during the 99B29 service program that required a gasket replacement to fix the problem.
Ford PowerStroke 3.0L V6
A dark blue 2018 Ford F-150 drives in sunny Dubai. – Darter/Getty Images
The Ford PowerStroke 3-liter V6 engine has been available on F-150 models since 2018 and later, but it never really caught on. The Ford diesel pickup engine was discontinued in 2021 as it struggled with a semiconductor shortage crisis and because it outsold its gasoline counterpart. Part of the reason people choose diesel trucks over gasoline trucks is towing capacity, but the 3-liter Power Stroke isn’t really any better in that regard than the existing gas engines.
Additionally, it is a very difficult engine to operate since it was designed for a Range Rover and not an F150. Regardless, major issues with 3-liter power strokes include crankshaft bearing failure that can lead to engine failure. The truck also suffered from EGR system issues, which could lead to poor performance and overheating issues. In addition to this, car owners also complained about DPF issues and EGT system issues.
When Getty’s Garage dug into the reasons for the discontinuation of the 3-liter Powerrinkle, he mentioned that “it costs a lot more to get relatively the same performance, so why buy a diesel engine?” This was also reflected in the availability of aftermarket support, meaning it never really caught on among 3-liter engines. Although it’s a fairly economical engine, it’s not strong enough to tow. Plus, it’s not the most reliable, and it’s certainly not what people want.
Ford 6.2L Boss
A red V8 Ford Raptor drives down a tree-lined intercity road. – Art Konovalov/Shutterstock
Introduced by Ford in 2010, the 6.2-liter Boss engine was initially reserved for the stunning V8 F150 Raptor until it was replaced by the new EcoBoost in 2019. Overall, it must be said that the 6.2 is not an engine you should shy away from as it has proven itself to be a fairly durable platform. However, it’s not perfect. Especially if you buy a used Ford F150 Raptor 6.2 and it has not been properly maintained. Things can take a turn for the worse quickly.
The three most common problems with the Ford 6.2L Boss engine include spark plug failure, broken valve springs, and oil leaks. In terms of spark plugs, this engine has 16. They are not easy or quick to replace. When Chris from I Do Cars disassembled a Ford 6.2L Boss V8, he mentioned that “some early ’62 engines were notorious for having broken valve springs,” which he later confirmed, saying he took one apart and found “a complete mess inside.”
Oil leaks are usually related to leaks inside the valve cover baffle on the right side of the valve cover. Ford issued TSB 15-0161, instructing dealers to replace affected cap assemblies to resolve the issue. Overall, the 6.2 is unlikely to be one of the F150 engines to avoid if properly maintained, but given the problems some examples encountered and the cost of fixing them, we decided to include it.
How we make a list
Close-up of the black front grille of the Ford F150. – PJ McDonald/Shutterstock
The Ford F-150 is an important part of American automotive culture. This is a truck that supports a large part of Americans’ daily lives. It’s been one of the best-selling vehicles for decades, and for good reason. It offers a strong balance of functionality, practicality and driving comfort, appealing to both those who need a work truck and those who just want a reliable, everyday vehicle.
However, given the size of the F-150 community, a wide variety of issues have been documented, and some engines have a reputation for problems. It’s important to stress that all of the engines discussed here are still reliable. We’re not talking about every 5.4-liter Triton engine will fail. Instead, based on a wealth of online data, these are the engines that emerge more likely Encountered a problem.
We reviewed numerous F-150 forum posts, mechanical expert reviews, teardowns, technical in-depth videos, information from the NHTSA database, Ford service bulletins, service schedules, and warranty extension notices. We also build on previous research our team has conducted on similar topics to ensure our lists are trustworthy and easily verifiable.
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Read the original article on SlashGear.
