800-900 RPM knocking in engine

[tb6g]

I'm surprised I haven't seen any posts about this, but my frustration has brought me here. I have a 2023 Bronco Raptor currently sitting at just over 4000 miles. I brought the Bronco to the dealership twice to attempt to address the issue and followed up a few more times. The problem is a very noticeable knocking from the engine between 800 and 900 RPMs. Above or below that range it disappears. Apparently there is a service bulletin of some sort stating that this is normal for the engine and there is nothing to fix. Everybody I have shown it to agrees that it would drive them as crazy as it is currently driving me. The service manager is currently digging a little deeper to see if he can get more information, but I'm to the point where I'm considering trading it in for a significant loss. No matter what, I know that I will not keep this vehicle long term if the issue persists. I love the vehicle overall, even if I was never a fan of the 3.0 turbo like many others. At any price point, this type of persisting engine noise would be unacceptable, but for 100k, I'm beyond disappointed. Is anyone else dealing with this?

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[FleshTuxedo]

Why would there be a TSB if it's 'normal'?

 

[tb6g]

Why would there be a TSB if it's 'normal'?

I didn't remember the proper nomenclature off hand. They showed me a "SSM" not a "TSB". I'm not sure how SSMs are handled in the long run. At first I thought it could be cam phasers, but it isn't as loud as the videos I've heard, the service department did not describe it as such, and it distinctly and replicatably happens consistently between 800 and 900 RPMs only as far as I can tell.

 

[brkdncr]

Before I had my first direct injection engine I would be thinking the engine is toast.

But now? The port+DI in the 2.7L is a sewing machine compared to the farm equipment in an all-DI motor.

I would guess it’s probably fine. I don’t know that eco boost engines have a history of rod knock.

 

[Fordified1]

Why do you run the engine between 800 and 900 rpm? That’s barely above idle and actually lugging it if accelerating. Maybe put it in sport mode to keep the rpm’s up?

 

[tb6g]

Why do you run the engine between 800 and 900 rpm? That’s barely above idle and actually lugging it if accelerating. Maybe put it in sport mode to keep the rpm’s up?

Once the engine settles, it idles closer to 600 RPM so it passes that range every time I accelerate or decelerate. I'd have to raise the idle to avoid that range altogether. It never sits there, but it's apparent everytime it passes.

 

[Fordified1]

Once the engine settles, it idles closer to 600 RPM so it passes that range every time I accelerate or decelerate. I'd have to raise the idle to avoid that range altogether. It never sits there, but it's apparent everytime it passes.

I meant try to spend less time in that rpm range. But I get it, I would be concerned also. I would be afraid of having a failure after warranty expires even if I could tolerate the annoying sound.

 

[PWillette]

Does the dealer have another Raptor you can compare too? I can't imagine that it's "normal"

 

[Nothing Left]

I’ve noticed a rough idle in that range as well. I have 11,700 miles and it just started within the last 2,000 miles. Mine idles at that range until the engine warms. Once it drops to normal idle it smoothes out. No knocking but can feel it.

 

[vrtical]

Ecoboost engines are noisy whether its the injectors or the cam phasers. Some are better then others, but as you find out its within acceptable range.

 

[tb6g]

Ecoboost engines are noisy whether its the injectors or the cam phasers. Some are better then others, but as you find out its within acceptable range.

I never liked the EcoBoost sound, but this one sounds different in a bad way. I previously had a 2.7L in a Wildtrak and a 3.5L in a Gen 3 Raptor and neither made this type of noise. I'm going to investigate some more and keep you guys posted. Something definitely seems off. I appreciate the feedback from everyone.

 

[CR_IN_UT]

I also have a Raptor and it sounds like a diesel all of a sudden. No Lights or warnings. What was the fix?

 

[Gibby1392]

I know this is old but I’ve had the same issue for awhile. Normally on cold starts I can hear and feel the rattle in my shifter from the 800-900 RPM range. I e had it at the dealer twice and they can find nothing wrong. One time I had my wife have it in gear with parking brake on and had her idle it 800-900 and seem like the noise is coming from my passenger side somewhere. If y’all find anything out please post your findings 🥹

 

[Area51BS]

I know this is old but I’ve had the same issue for awhile. Normally on cold starts I can hear and feel the rattle in my shifter from the 800-900 RPM range. I e had it at the dealer twice and they can find nothing wrong. One time I had my wife have it in gear with parking brake on and had her idle it 800-900 and seem like the noise is coming from my passenger side somewhere. If y’all find anything out please post your findings 🥹

Just an fyi. The 2.3 has this when cold at times. More so in cooler weather. Sounds more like the 10speed than the engine. Easy on the pedal and it won’t make the noise. And I never hear it with these summer temps.

 

[FourHorses]

Hear me out. Had an explorer platinum with that same 3.0. Same kinda sound. Same rpm’s. Couldn’t find anything on it or get them to fix it. Stumbled across the explorer st forum, found out it was normal for the vehicle, but drove folks like us crazy. It was a flex pipe on the exhaust. It may have a similar setup. Worth a look.

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