Identify This Clicking Noise After Short Pull - Led to Misfire at Light Throttle

[NHMaverick]

2022 Ford Maverick EcoBoost 2.0L AWD w/ 4k Tow Package

The truck has 34k miles and no prior mechanical issues or failures of any kind. We had some cool weather on the way home the other night so I did a pull to maybe 30 or 40 mph and heard this noise when I let off the throttle. My best guess is that it's related to the recirc/bypass valve or the wastegate. Did the bypass valve shred itself and send pieces through the turbo?

Attempting to identify the noise (and the cause of the noise) at the end of the short pull in the video. Immediately following that there was a noticeable misfire on light throttle acceleration, but nothing apparent under harder acceleration. No CEL. It has continued the following day - relatively stable idle warm and cold, rough/stumbling on light throttle up to about 2k rpms, and then smooth from there. Goes into boost and pulls normally at part throttle, only stumbles under very light throttle such as when trying to maintain speed. Did throw a CEL for cylinder 2 misfire on the way to my work.

It does hold boost under acceleration, runs 2-8 psi of vacuum at cold start, 9-10 psi vacuum warm, so I doubt any charge pipes blew off. I gave everything I could reach a gentle tug and nothing feels loose. The truck was just reflashed by the dealer for multiple recalls. I wasn't sure if the misfire was all in my head or not so I disconnected the battery (there was no CEL on at the time). Whatever happened has created a mechanical issue (regardless of whether the initial problem was caused by the tune).


Any thoughts? Has anyone experienced this before? If anyone's had a bypass/recirc valve malfunction or destroy itself, I'd love some insight on what it looked like so I can compare if I pull mine out. I am really hoping it didn't grenade itself and run through the turbo.


Update 7/26: Bought some plugs since I've heard a lot of people do those around 30k. Pulled the old ones and cylinder 2 plug shows signs of being impacted by something. Time to call the dealer and let them diagnose.

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[Bwicka]

I think there has been issues with the factory electronic blow off/ bypass valve . And they are against the firewall about center of truck ( back of engine )

 

[awscheetz]

2022 Ford Maverick EcoBoost 2.0L AWD w/ 4k Tow Package

The truck has 34k miles and no prior mechanical issues or failures of any kind. We had some cool weather on the way home the other night so I did a pull to maybe 30 or 40 mph and heard this noise when I let off the throttle. My best guess is that it's related to the recirc/bypass valve or the wastegate. Did the bypass valve shred itself and send pieces through the turbo?

Attempting to identify the noise (and the cause of the noise) at the end of the short pull in the video. Immediately following that there was a noticeable misfire on light throttle acceleration, but nothing apparent under harder acceleration. No CEL. It has continued the following day - relatively stable idle warm and cold, rough/stumbling on light throttle up to about 2k rpms, and then smooth from there. Goes into boost and pulls normally at part throttle, only stumbles under very light throttle such as when trying to maintain speed. Did throw a CEL for cylinder 2 misfire on the way to my work.

It does hold boost under acceleration, runs 2-8 psi of vacuum at cold start, 9-10 psi vacuum warm, so I doubt any charge pipes blew off. I gave everything I could reach a gentle tug and nothing feels loose. The truck was just reflashed by the dealer for multiple recalls. I wasn't sure if the misfire was all in my head or not so I disconnected the battery (there was no CEL on at the time). Whatever happened has created a mechanical issue (regardless of whether the initial problem was caused by the tune).


Any thoughts? Has anyone experienced this before? If anyone's had a bypass/recirc valve malfunction or destroy itself, I'd love some insight on what it looked like so I can compare if I pull mine out. I am really hoping it didn't grenade itself and run through the turbo.


Update 7/26: Bought some plugs since I've heard a lot of people do those around 30k. Pulled the old ones and cylinder 2 plug shows signs of being impacted by something. Time to call the dealer and let them diagnose.

What ended up happening? My engine blew up due to cylinder #2 sparkplug destroying a piston.
Got my new engine after 2 months and on the way home I'm getting misfire codes on #1 and #4 cylinder. I'm calling my dealer back tomorrow.

 

[NHMaverick]

What ended up happening? My engine blew up due to cylinder #2 sparkplug destroying a piston.
Got my new engine after 2 months and on the way home I'm getting misfire codes on #1 and #4 cylinder. I'm calling my dealer back tomorrow.

I don't know exactly what the noise was, but the spark plug in cylinder #2 broke. The center insulator was no longer attached and could slide up and down. I'm not sure if the noise was the insulator moving up and down, or if something else went through that cylinder.

The plug never actually broke into pieces, it came out in one piece. I ended up having a dealer look at it as I had taken some pictures and it looked like there was some potential damage in the cylinder, but it was just reflection from my borescope light reflecting off oil droplets, but when since the cylinder had no combustion. They confirmed that there was no damage, and replaced the plug under warranty.

I did check the bypass valve, and it was operating correctly.


Sorry to hear that happened to you, sounds like potentially a similar experience to mine, except your plug must have actually broken into pieces and then bounced around?

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