Hybrid Maverick Power Loss, P1061 Code, Faulty Rod Bearing, Engine Replacemnet

[Gergify]

EDIT: As of June 26th, it seems the problem relates to the recent CSP about the faulty rod bearing. My Maverick is getting the one-time engine replacement. Timing chain replacement noted below appears to have been unnecessary.

Engine swap was completed Aug 5th, will report if further issues arise.

I updated the title to better reflect the threads content.

TDLR timeline:

• May 6th: Problem first occurred. Dropped off at dealer
• May 8th: Vehicle returned after 'software resets'
• May 17th: Issue occurred again. First dealership reset software to make drive-able, but did not offer rentals, so I took it to another dealer. Problem re-occurred again on way to second dealership.
• May 22th: Vehicle returned, after dealership conducted 'diagnoses and software fixes'
• May 23rd: Issue occurred again, and vehicle returned to dealer
• June 5th: Buy back request submitted to Ford
• June 6th: Vehicle returned from dealer. extension work conducted (replacement of knock sensor and all timing chain components)
• June 14th: Problem occurred again. Vehicle dropped back off at dealer. Ford buy back 'still in review', should hear back in next 5 days. Contacted lawyer to review legal options in the event Ford denies buy back.
• June 18th: Dealer called and said they haven't found anything, more updates EoW.
• June 19th: Ford denies buy back request
• June 21st: Ford buy back team denies my escalation, stating they will not reverse their decision.
• June 26th: Dealer is now working to replace the entire 'long block' . Waiting on parts. They were unable to give me a time frame
• July 29th: Crate engine received from Ford and swap begins.
• August 5th: Swap completed and vehicle picked up. Will report if any further issues come up.

I posted a while back about an issue I was having with my Maverick Hybrid losing power randomly. After nearly a month in the shop, I finally got my truck back.

The dealer could not give me the exact cause of the issue. It appears Ford engineers told them to 'shotgun' it and replace everything related in hopes they solve the issue, so I guess time will tell if it's really fixed. Essentially they did the following:

-Replaced knock-sensor
-Replaced Timing Chain
-Replaced Camshaft sprockets
-Replaced Chain Tensioner

Here is the summery of the work completed:

Thankfully everything, including nearly a month of rental, was included under warranty. Still, having tear apart the front end and conduct major repairs on a vehicle under 20k miles is concerning.... I'm in contact with Fords Buy Back team, needless to say this experience has made me very nervous about long term reliability. I'm considering my options moving forward, and whether to keep the truck (and purchase extended warranty) or ditch Ford entirely.

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[Rockingchair]

Don't buy a warrantee, negotiate for extended coverage due to the repair.

 

[colinl]

Never seen anyone with this issue... Your 2 threads are literally the only I've seen on MTC and across several Facebook groups I follow.

I'm pretty comfortable saying it was a fluke, and if it was properly repaired I'm confident it won't be an issue.

I doubt you'll be eligible for buy back but then again I've never pursued such a thing. I have had engine repairs done under warranty and also out of warranty on various brands, but not including Ford.

 

[papak]

On these motors, neither the cam gears or the harmonic balancer are keyed. The are fixed by a one time use bolt and an industrial diamond coated washer. The tensioner is hydraulic. If these parts were installed correctly in the manufacturing process, it is highly improbable that any of them would fail at the 20k point. I have rebuilt several of these motors with no issues. This is a extraordinarily improbable failure mode.

 

[Gergify]

On these motors, neither the cam gears or the harmonic balancer are keyed. The are fixed by a one time use bolt and an industrial diamond coated washer. The tensioner is hydraulic. If these parts were installed correctly in the manufacturing process, it is highly improbable that any of them would fail at the 20k point. I have rebuilt several of these motors with no issues. This is a extraordinarily improbable failure mode.

Very interesting. So it sounds like it was probably a manufacturing error rather than an engineering one.

 

[papak]

It's my understanding that these motors are robotically assembled. Recall a video from several years ago of the Porsche assembly line with the engines being put together in 22 minutes! I wouldn't be surprised if this was the case with Ford as well.

 

[colinl]

Very interesting. So it sounds like it was probably a manufacturing error rather than an engineering one.

respectfully... yes, of course that is the case.

 

[Snox801]

So by losing power are you talking limp mode?
Any specific code it tossed your way? How often did this happen?

 

[Connect]

That's a tough one. It would make me nervous for sure about keeping it but since there is nothing else out there like it, I think I would have a hard time finding a replacement.

I agree with what someone else said about try to get them to agree to extended the warranty coverage. Or is the buy back offer is right I would give another one a shot

 

[OneAlienBoi]

Very interesting. So it sounds like it was probably a manufacturing error rather than an engineering one.

Seems like, and a very rare manufacturing error considering this is the only one we've heard out out of more than 300k mavericks. The 2.5 duratec used in the maverick has been around for ages, and is basically the textbook example of a bulletproof engine from what I've heard.

 

[FullMetalGear]

https://www.mavericktruckclub.com/f...ybrids-losing-drive-train-engine-power.47446/

Is this similar to the issue you've been having?

 

[Chase300]

It's my understanding that these motors are robotically assembled. Recall a video from several years ago of the Porsche assembly line with the engines being put together in 22 minutes! I wouldn't be surprised if this was the case with Ford as well.

If true, then highly improbable of the robot screwing up one time, there would be a whole batch of them. So his problem is most likely not fixed and is something else if your assumptions are correct or there would be more instances of this issue.

 

[MetalsGeek]

I kinda, sorta think I may not be the only person wondering what your symptoms of power loss were. It seems that a hybrid might make this more difficult to quantify, and a dealer would need to see hard evidence of a problem before starting any warranty work. e.g. Were there any MIL codes? Did this occur during hard acceleration? Did RPMs vary as well as the "neck snapping" feel of raw power? (LoL)

 

[trumpet77]

I’m an auto tech student so my thoughts are worth what you paid, but seems odd to “shotgun” parts focused on camshafts but not crankshaft.

Regardless, hope the fix takes care of it.

 

[JokingJ]

Seems like, and a very rare manufacturing error considering this is the only one we've heard out out of more than 300k mavericks. The 2.5 duratec used in the maverick has been around for ages, and is basically the textbook example of a bulletproof engine from what I've heard.

I mean, define bulletproof? There's currently still a class action at play about a fairly large run of those same engines seizing, consequently suffering a block breach, puncturing down to the oil pan and ultimately starting fires... Perhaps prior to that, I'd have agreed, but Ford has also been pretty cagey about what they actually changed in newer engines to avoid that issue, and they haven't offered an actual fix yet for affected customers AFAIK -- other than drilling holes to let oil drain in the event of the failure described above, which isn't confidence inspiring (if someone does know more, please correct/share).

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