Connecting rod bearing finally caught up with me

[techparadox]

Hi all - long time browser, finally decided to sign up for an account after sitting around and twiddling my thumbs while waiting on the dealership for the last two weeks and change. As you can see in the sidebar, '22 Maverick XLT Hybrid. Was "new to me" as of January '23, but was effectively new as the original owner had only put around 1500 miles on it. I've since added another 44,000 to that tally (just over 45K total) and it's been serving me well as my daily driver - up until the Tuesday after Labor Day.

I was headed to work when I got the dreaded loss of power and "service vehicle" notice, immediately dropping into limp mode. Fortunately I wasn't that far from home, so I made it back to the house and started making phone calls. Got it towed into the dealership and picked up a loaner, and a few days later I got the dreaded call. "Looks like it's the connecting rod and bearing", they said. "Gonna need a new engine. Probably going to take a couple weeks to get it in." Oof.

They called last Friday asking if I had any other service records for the truck as they were submitting it for warranty, but no word since. In the meantime, I've been getting Deep Sleep warnings from the truck through FordPass. So, here I sit, hoping this gets covered under CSP 23N06, or at minimum the remaining powertrain warranty it had when I got it, and that the battery isn't messed up by the time I finally get it back.

No real questions, just wanted to vent. Thanks for letting me rant. Now I'm off to go put gas in the land yacht of a loaner they gave me, yet again.

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[Cherokee]

Odd for the Hybrid ICE

 

[dhaskit]

Hi all - long time browser, finally decided to sign up for an account after sitting around and twiddling my thumbs while waiting on the dealership for the last two weeks and change. As you can see in the sidebar, '22 Maverick XLT Hybrid. Was "new to me" as of January '23, but was effectively new as the original owner had only put around 1500 miles on it. I've since added another 44,000 to that tally (just over 45K total) and it's been serving me well as my daily driver - up until the Tuesday after Labor Day.

I was headed to work when I got the dreaded loss of power and "service vehicle" notice, immediately dropping into limp mode. Fortunately I wasn't that far from home, so I made it back to the house and started making phone calls. Got it towed into the dealership and picked up a loaner, and a few days later I got the dreaded call. "Looks like it's the connecting rod and bearing", they said. "Gonna need a new engine. Probably going to take a couple weeks to get it in." Oof.

They called last Friday asking if I had any other service records for the truck as they were submitting it for warranty, but no word since. In the meantime, I've been getting Deep Sleep warnings from the truck through FordPass. So, here I sit, hoping this gets covered under CSP 23N06, or at minimum the remaining powertrain warranty it had when I got it, and that the battery isn't messed up by the time I finally get it back.

No real questions, just wanted to vent. Thanks for letting me rant. Now I'm off to go put gas in the land yacht of a loaner they gave me, yet again.

I’m sorry to hear about that. Hopefully they will have you back up and running soon and will cover it all under the factory warranty.
Keep us updated, my friend.

 

[Scott Asheville]

As somebody who's ecoboost is in the shop now (who knows how long) because it won't run more than five seconds, I can attest that it's just statistics and luck. Engines are complicated and malfunction at some given rate. The luck part is whether or not it's your engine that breaks or somebody else's engine.

OP, I not only feel your pain. I share your pain.

 

[AutobahnSHO]

Sorry to hear!! Hopefully it's all covered by warranty!

 

[Chops]

Should be covered by powertrain warranty if you’ve been doing the 10,000mi/12mo whichever comes first requirement. If they reject the warranty because you haven’t - let us know? Never heard of that happening…

 

[HeyBales]

Hey - at least original owner had the recalls done that included the software update to see that issue before it really threw a rod.

You can read more in the 1st Similar thread below your post.

For safety sure thought that warranty went to next owner, hope it does since they knew some 2.5's have the potential from manufacturing defect, just not which ones exactly.

Deep sleep mode notices, that's to save the batter, it doesn't ruin the battery - they have probably left doors open too often and now you are merely seeing what was going to happen anyway.
Tell them to do their normal battery check as it seems techs may have done that - and at least get a full charge out of it.
Perhaps they'll throw in a free replacement if they are convinced they did it.
Or plan on getting your own AGM when you get it back.

 

[Jah.]

Good luck .

 

[techparadox]

Should be covered by powertrain warranty if you’ve been doing the 10,000mi/12mo whichever comes first requirement. If they reject the warranty because you haven’t - let us know? Never heard of that happening…

That's where I'm worried I might have screwed myself. I missed the first couple regular maintenance checks over-mileage, mainly because life kept getting in the way of getting it in to the shop. Every one after that has been within 10K or a year, but we know how corporate entities can be when it comes to shafting the customer on technicalities.

 

[techparadox]

Hey - at least original owner had the recalls done that included the software update to see that issue before it really threw a rod.

Funny enough, I was the one that took it in for most of the updates. Original owner actually initiated a buyback because of some battery-related error. They told him they could fix it, he said "nope" and made them take it back, and it ended up back on the lot with the remainder of the warranty after they did fix it. One of the weirdest coincidences I've ever seen, because I just happened to see it, it was the color and kit I wanted, and my current vehicle at the time (a Pontiac G6 with a failing transmission) was in dire need of replacement.

 

[icegradner]

Odd for the Hybrid ICE

Not really, not for a 22. This is very likely related to the engine fire recall on all 22 and some early 2023 Hybrids for the 2.5L ICE, which may have a poorly machined crankshaft.

 

[Propane Burning Man]

Did they actually tear the engine down and looked at the bad rod bearing with their own eyes? I am skeptical about this diagnosis. Should have been knocking like crazy if the rod bearing goes bad. Reminds me of the time 25 years ago when I bought an old Toyota MR2 from a private seller. He told me the dealer told him 1 cylinder had no compression and he needed a new engine. He did not want to spend $1000's on a new engine, and decided to sell as is to whoever. He started it up when I was there interested in buying it. It was only runnning on 3 cylinders. I could see the plug wires were old and crusty and looked like the originals. So I figured new wires and plugs would solve the problem. Bought it for $500. Put new plugs and wires in it and it was screaming like a Ferrari. Drove the crap out of it for several years! Sold it to my buddy for $1000, he drove it for several years until he got hit by another driver and it was totaled and he got $2000 from the insurance.

 

[colinl]

Did they actually tear the engine down and looked at the bad rod bearing with their own eyes? I am skeptical about this diagnosis. Should have been knocking like crazy if the rod bearing goes bad.

one never really knows what another person knows, but based on your MTC account creation date and that you own a '24, I'm going to assume you don't know about this root issue.

there was a batch of MY21-23 hybrid 2.5L engines that had some kind of manufacturing defect. (probably bad rod bearings from supplier, but perhaps it was a machining tolerance or assembly issue. we don't know.) it wasn't just the maverick, it was other vehicles with the 2.5 atkinson cycle engine as well. https://www.mavericktruckclub.com/f...-100k-miles-for-dtc-p1061-and-or-p032f.50899/

Ford created new DTCs to detect this condition. when those are set, the work is done, which is a new a longblock.

I don't believe anyone has posted pics of a torn-down engine to show actual rod bearing or other lower engine damage, because when the techs pull the longblock this isn't required and they don't have the hours to spare since Ford specifies the allowed time. but to address your key contention, yes, it's possible that the damage is not yet severe enough to cause noise that is noticeable to the average owner. I can't remember anyone with this issue reporting catastrophic failure, like a piston or rod ejecting from the block, but I bet that has happened based solely on the number of affected vehicles.

 

[icegradner]

one never really knows what another person knows, but based on your MTC account creation date and that you own a '24, I'm going to assume you don't know about this root issue.

there was a batch of MY22 hybrid 2.5L engines that had some kind of manufacturing defect. (probably bad rod bearings from supplier, but perhaps it was a machining tolerance or assembly issue. we don't know.) it wasn't just the maverick, it was other vehicles with the 2.5 atkinson cycle engine as well. https://www.mavericktruckclub.com/f...-100k-miles-for-dtc-p1061-and-or-p032f.50899/

Ford created new DTCs to detect this condition. when those are set, the work is done, which is a new a longblock.

I don't believe anyone has posted pics of a torn-down engine to show actual rod bearing or other lower engine damage, because when the techs pull the longblock this isn't required and they don't have the hours to spare since Ford specifies the allowed time. but to address your key contention, yes, it's possible that the damage is not yet severe enough to cause noise that is noticeable to the average owner. I can't remember anyone with this issue reporting catastrophic failure, like a piston or rod ejecting from the block, but I bet that has happened based solely on the number of affected vehicles.

There was one fellow with a 22 Hybrid on the Maverick Reddit group that had an engine fire due to a block breach Back in 2023. That was the only case I’ve seen of it happening though. I recall it vividly because he talked about how long he had to wait for repairs. I think he ended up lemon lawing it.

 

[colinl]

There was one fellow with a 22 Hybrid on the Maverick Reddit group that had an engine fire due to a block breach Back in 2023. That was the only case I’ve seen of it happening though.

I think I missed that one, but boy do I remember the guy who had an engine bay fire and then subsequent discussion revealed that he'd had smoke, inspected under the hood and noticed he had forgotten to reinstall the engine oil cap after changing the oil which (rather predictably) sprayed oil in the engine bay. he replaced the cap, kept driving and THEN the engine bay caught on fire.

except his thread of course didn't start with that. it was much more like OMG Ford made a dangerous product my hybrid caught on fire.

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