F-150 Ecoboost: Plastic Oil Pans?

The Ford F-150 is a popular truck, and its EcoBoost engines have been praised for their reliability and performance. However, some models, including the 2015-2019 F-150s, were found to have plastic oil pans and drain plugs, which are prone to leaking. This issue has been widely discussed on forums, with some owners reporting leaks before their trucks even hit 20,000 miles. While Ford has issued technical service bulletins and made changes to the pan design, some owners have opted to replace the plastic pans with metal ones. The transmission pan, on the other hand, remains plastic. The 2023 F-150 3.5L Ecoboost is reported to have an aluminum pan and drain plug.

The plastic oil pan is prone to premature leaks

The leaks are caused by a combination of factors, including poor room-temperature vulcanizing (RTV) silicone sealant jobs from the factory and the warping of the plastic oil pans. The warping creates gaps between the pan and the mounting surface on the engine block, exacerbating the problem of shoddy silicone application. As a result, owners have had to replace the pan multiple times due to recurring leaks.

In response to this issue, Ford revised the design of the 2.7L oil pan during the 2018 model year, supposedly eliminating the leaking issue on some earlier 2.7L engines. Additionally, in 2019, Ford issued two technical service bulletins for 2.7L and 3.0L EcoBoost vehicles, updating the replacement procedure and recommending the use of a press-in-place gasket instead of the RTV silicone gasket.

Despite these efforts, there are still concerns about vehicles in operation that have not been addressed. Furthermore, the confusing design of the plastic oil pan drain plug has also led to leaks due to improper installation. The drain plug for EcoBoost engines with a plastic oil pan is intended for one-time use, as the silicone O-ring has a limited lifespan when subjected to extreme heat.

The plastic oil pan leak problem has been a persistent headache for Ford owners and service professionals, who must be vigilant about the issues to avoid potential blowback from the automaker.

The plastic oil pan's drain plug is also problematic

The plastic oil pan drain plug is also problematic. The first problem is the two tabs that are shown in the image below. These two tabs are there to lock the drain plug into place when hand-tightened. However, installers often mistakenly believe they need to lift or flex the tabs to unlock and remove the plug, which is incorrect and usually results in breakage. To remove the Motorcraft FT4Z6730A drain plug, simply turn it counterclockwise by hand while pulling the plug away from the pan, and the tabs will unlock. It is important to note that the plug may be difficult to remove after extended exposure to heat, and a pair of pliers may be necessary. When installing the new plug, it is recommended to only tighten it by hand, as using a wrench or any other tool may cause over-tightening, leading to breakage or leakage.

The drain plug for EcoBoost engines with a plastic oil pan is designed for one-time use. While Ford has not provided official guidance on this, other OEMs with similar applications, such as BMW and Mercedes Benz, specify their plastic drain plugs as single-use. Additionally, the plug features a silicone O-ring, which has a limited lifespan when subjected to extreme heat. Reusing the plug for multiple oil changes can lead to rapid leakage.

During their research, the authors even found instances of the drain plug leaking before the first oil change. In one case, the owner of an F-150 discovered a leak immediately after removing the skid plate that covers the oil pan, despite the truck only having 9,000 miles on it.

The issues with the oil pan and drain plug have caused ongoing headaches for Ford owners of various models featuring EcoBoost engines. Service professionals should also be cautious of these problems, as automakers often cast blame on independent installers when issues arise. Therefore, it is crucial for anyone performing oil changes on these vehicles to be aware of these potential faults and take the necessary precautions to avoid future problems.

Ford has issued technical service bulletins for the 2.7L and 3.0L EcoBoost engines

Ford has issued technical service bulletins (TSBs) for its 2.7L and 3.0L EcoBoost engines, which are known to have issues with their plastic oil pans. The TSBs provide updated replacement procedures and, in some cases, recommend using a press-in-place gasket instead of the RTV silicone gasket.

The plastic oil pans on these engines are prone to premature leaks, with some Ford owners reporting leaks before their vehicles reached 20,000 miles, and even as early as 160 miles. The leaks are caused by a combination of warping of the plastic oil pans and poor room-temperature vulcanizing (RTV) silicone sealant jobs from the factory.

In 2019, Ford issued two TSBs for the 2.7L and 3.0L EcoBoost engines: TSB 19-2205 for the Ford F-150, and TSB 19-2219 for the Ford Edge, Ford Fusion, Lincoln Continental, Lincoln MKZ, and Lincoln MKX. TSB19-2249, later superseded by 19-2387, added the Lincoln Nautilus to the list and stated that the updates should not be installed on vehicles produced between 2015 and 2017.

The 2.7L EcoBoost engine was introduced in 2015 and has since received multiple updates to address the leaking oil pan issue. The second-generation 2.7L EcoBoost, introduced in the 2018 Ford F-150, features a compacted graphite iron (CGI) block and produces an additional 25 lb-ft of torque. This updated engine also includes port fuel injection, reduced internal friction, and a new exhaust gas recirculation system.

The 3.0L EcoBoost engine, introduced in 2016, is a twin-turbocharged V6 that produces between 350 and 400 horsepower. It has gradually replaced the 3.7L Ti-VCT Cyclone V6 engine in various vehicles, including the Lincoln MKZ, Continental, Aviator, Ford Explorer, and the 2022 Ford Bronco Raptor.

Ford switched back to an aluminium oil pan for the 3.5 EcoBoost in March 2018

The plastic oil pans were prone to premature leaks, with some new Ford owners noticing leaks before hitting 20,000 miles, and at least one owner reporting a leak after only 160 miles. The leaks were caused by a poor RTV silicone sealant job from the factory, which, when combined with the fact that the plastic oil pans could warp and become uneven, created gaps between the pan and the mounting surface on the engine block.

In response to this issue, Ford published numerous technical service bulletins and eventually switched back to an aluminium oil pan for the 3.5 EcoBoost engine in March 2018. However, it's important to note that earlier 2018 vehicles may still have the plastic pan, as the switch was made during the model year.

The plastic oil pan's design was revised during the 2018 model year

The plastic oil pan design was revised during the 2018 model year, supposedly eliminating the leaking issue on some earlier 2.7L engines. In 2019, Ford issued two technical service bulletins for 2.7L and 3.0L EcoBoost engines, updating the replacement procedure. This included using a press-in-place gasket instead of the RTV silicone gasket previously used.

The 2018 model year saw Ford transition from plastic to aluminum oil pans in the 3.5 EcoBoost engine, with the change taking place after approximately March 18, 2018. However, some earlier 2018 vehicles may still have the plastic pan. The transmission pan, on the other hand, remains plastic.

The plastic oil pan leak problem was well-known among Ford owners and acknowledged by the automaker, who published numerous technical service bulletins on the issue. Leaks were most common with 2.7L, 3.0L, and 3.5L EcoBoost engines, especially in 2017 F-150s. The root cause was often a poor RTV silicone sealant job from the factory, exacerbated by warping of the plastic oil pans.

In response to the issues with the plastic oil pans, Ford F-150 owners had several options. Some opted to switch to a metal oil pan, which required removing 16 bolts and addressing the oil pickup tube and block stiffener. Others chose to follow Ford's revised replacement procedure, which included using a press-in-place gasket.

The plastic oil pan and drain plug issues caused an ongoing headache for Ford owners of various models featuring EcoBoost engines. Service professionals also needed to be aware of these faults, as automakers often cast blame on independent installers when problems arise.

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