Ford Expedition 4th Gen

3.5L twin-turbo V6, Gen 2 from 2017 — the big change was adding port injection alongside direct injection, which eliminated the carbon buildup problem. In High Output Raptor trim it makes 450 hp, standard F-150 gets 375-400 hp. Not an emotional engine — it sounds like an efficient twin-turbo V6, which is exactly what it is. But the torque from 2,500 rpm onwards is relentless, holding flat until 5,000 rpm before falling off a cliff. Cam phaser failure on 2017-2020 is THE topic: cold-start rattle, worst case chain skip. Ford CSP 21N03 expired, repair costs $3,000-5,000. Exhaust manifold studs snap from turbo heat cycling. Plastic valve covers crack around 60k miles — an engineering choice that should have been aluminum. Wastegate rattle is cosmetic but annoying. Different 10R80 calibration in the Raptor. Oil changes every 5,000 miles with full-synthetic 5W-30.

• !! Cam Phaser Failure (2017-2020) from 80,000 km

  THE Gen2 topic: hydraulic phasers fail from ~50k miles. Ford CSP 21N03 (expired). $3-5k repair. July 2018 and October 2019 revisions improved the parts.

  Symptoms: Knock/tick at warm idle, CEL P0011/P0012
  800–5,000 $
  Ad ML3Z-6C525-A cam phaser 3.5 EcoBoost Gen2HL3Z-6268-A timing chain 3.5 EcoBoost 2017-2020HL3Z-6M280-A VCT solenoid 3.5 EcoBoost Gen2HL3Z-6279-B phaser bolt 3.5 EcoBoost
• !! Exhaust Manifold Warps — Studs Break from 90,000 km

  Turbo heat + original design with too few studs → warping and breakage. Ticking on cold start.

  Symptoms: Ticking/squeaking on cold start
  600–2,500 $
  Ad BL3Z-9430-D exhaust manifold RH 3.5 EcoBoostBL3Z-9431-D exhaust manifold LH 3.5 EcoBoostexhaust manifold stud 3.5 EcoBoost F-150
• !! Turbo Coolant Line Leak from 80,000 km

  The bi-turbo coolant supply and return lines become brittle from thermal cycling and leak. Sudden coolant loss under load can cause overheating — especially dangerous when towing.

  Symptoms: Sweet smell, low coolant without visible puddle, overheat warning while towing
  1,200–3,500 $
  Ad turbo coolant line 3.5 EcoBoost F-150turbo coolant supply return line kit Ford 3.5L

+ 3 more engine weaknesses + vehicle weaknesses