Ford F-150 Raptor
3.5L EcoBoost V6 Gen2 — revised twin-turbo with port injection (no more carbon). Cam phaser failure on 2017-2020 is THE topic (Ford Customer Satisfaction Program 21N03, expired). Exhaust manifold studs break from turbo heat. Plastic valve covers crack. Still: the most popular F-150 engine and in Gen2 form significantly more reliable than Gen1.
Raptor Gen2 3.5 HO — 450 hp, cam phasers, desert madness
450 hp high-output twin-turbo: the Raptor that defined the class. Desert running at 100 mph, Fox shocks, bead-lock wheels. Cam phaser issues like the standard 3.5L. Nobody buys a Raptor as transportation — it is an experience.
Engine Weaknesses 6
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
Turbo heat + original design with too few studs → warping and breakage. Ticking on cold start.
Symptoms: Ticking/squeaking on cold start
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
HPFP failures are a known issue on the 3.5 EcoBoost. In severe cases the pump can fragment and damage the cylinder head — resulting in $4,800+ repairs. Some trucks have needed three pumps before 100k miles.
Symptoms: Hard start, P0087 fuel rail pressure low, hesitation under boost, metallic knock on pump failure
Plastic + heat cycles + mechanic error → crack. Oil on exhaust manifold. Parts backordered >6 months at times.
Symptoms: Oil smell, oil on exhaust manifold
Well-known Gen2 issue: both turbo wastegate flaps develop excessive play and rattle loudly. Can recur after turbo replacement. When the flap no longer seals, underboost codes are triggered.
Symptoms: Loud rattle on cold start lasting up to a minute, P0299 underboost when flap play is severe
Vehicle Weaknesses 6
10R80 auto: vibration at 35-45 mph like driving over rumble strips. Torque converter clutch slips. CDF clutch drum migration. Multiple TSBs, $5,500-7,000 repair.
Same issue as 12th Gen — 2014-2017 models with 3.5L EcoBoost. Safety recall covers free replacement of master cylinder and booster.
TSBs 15-0052 and 16-0155: door latch cables on the 2015-2017 F-150 can kink or freeze, causing doors to appear closed while actually unlatched — a safety hazard at speed.
Recall 21S53 for 2018 F-150: tailgate latch design allows the pawl to unlatch under normal driving conditions. Ford replaced both left and right latches on ~57,000 trucks.
Primer defect on aluminum body (2015-2019): paint peels from roof, hood, sides. Class action.
Front and rear pinion seals are a known weak point on the F-150. Repeat failure is common because many shops skip resetting bearing preload — without this step the new seal leaks again quickly.