Engine failure at 45k miles

[bodie_38]

Truck is a 2023. I bought it used/certified at a Ford dealer in January with 35k miles and have taken it on several road trips without issue. Oil was changed at about 40k miles. About 100 miles from home on the most recent, a big orange wrench appeared on the display for a few seconds. There was no chime or scary alert message so I assumed it was a maintenance reminder. When I stopped for gas, I checked the app and saw that it was for "Powertrain Malfunction/Reduced Power" and instructed me to contact an authorized dealer as soon as possible. When I started driving again, I did notice that the power was reduced (no boost) and continued home for another 50 miles. It was Saturday night so I made an appointment to bring it in first thing Monday. I did not drive it Sunday but when I started it Monday to go to the dealer, it sounded rough and rattley. On the way, I got a momentary low oil pressure warning when I let off the gas but the measurement screen still showed 30+psi if I was on the gas so I continued to the dealer.
When the dealer finally got to it, they told me there was only about 1 quart of sludge in the oil pan and the engine was toast.
Ford covered the repair, replacing the engine and turbos but they can't tell me what happened. I KNOW 6+ quarts of oil were put in it at 40k miles and the dealer said there were no signs that it leaked out so what causes an engine to consume 5 quarts of oil in 5000 miles?
I'm taking it back this week because it feels underpowered. Normal driving seems fine but acceleration seems weak and it only shows 10 psi boost at WOT.
Has anyone else dealt with something similar?
Looking for opinions on what happened and advice if dealer claims "nothing wrong".
Thanks!

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[CitrusBronco]

I dont have an answer for you, sorry.

That’s a lot of oil consumption.
I suspect you changed the oil? Is that why you “know” 6 qts were added.

Well this is a good reminder for everyone that when a check engine light comes on, pull over and check.

 

[VirginiaHeritage]

Your member info says Raptor. Is that the truck we’re talking about? I thought the 3.0 was a 7 qt fill.

 

[stevenstommyboy1]

Sorry about your truck. Should have not driven it after the first signs of issues. I know it’s easy to say but check the oil when you see something like that. Hope they get it squared away for you.

 

[Kevin Scarbel]

Truck is a 2023. I bought it used/certified at a Ford dealer in January with 35k miles and have taken it on several road trips without issue. Oil was changed at about 40k miles. About 100 miles from home on the most recent, a big orange wrench appeared on the display for a few seconds. There was no chime or scary alert message so I assumed it was a maintenance reminder. When I stopped for gas, I checked the app and saw that it was for "Powertrain Malfunction/Reduced Power" and instructed me to contact an authorized dealer as soon as possible. When I started driving again, I did notice that the power was reduced (no boost) and continued home for another 50 miles. It was Saturday night so I made an appointment to bring it in first thing Monday. I did not drive it Sunday but when I started it Monday to go to the dealer, it sounded rough and rattley. On the way, I got a momentary low oil pressure warning when I let off the gas but the measurement screen still showed 30+psi if I was on the gas so I continued to the dealer.
When the dealer finally got to it, they told me there was only about 1 quart of sludge in the oil pan and the engine was toast.
Ford covered the repair, replacing the engine and turbos but they can't tell me what happened. I KNOW 6+ quarts of oil were put in it at 40k miles and the dealer said there were no signs that it leaked out so what causes an engine to consume 5 quarts of oil in 5000 miles?
I'm taking it back this week because it feels underpowered. Normal driving seems fine but acceleration seems weak and it only shows 10 psi boost at WOT.
Has anyone else dealt with something similar?
Looking for opinions on what happened and advice if dealer claims "nothing wrong".
Thanks!

Who changed the oil?

 

[Kevin Scarbel]

Your member info says Raptor. Is that the truck we’re talking about? I thought the 3.0 was a 7 qt fill.

7 quarts is the correct fill for a 3.0L including the filter.

 

[bodie_38]

Yes, it is a Raptor. Yes, I changed the oil and yes I know the manual says 7 quarts. The dipstick read full at 6 so I put in another half quart. It showed over full at 6.5 so I didn't want to put any more in.

 

[Brian_B]

No leak - if it’s burning oil that much you would probably see smoke and gotten a code about it

Not many other places for 5-6 qts of oil to go in 5k miles

 

[Razorbak86]

Ford covered the repair, replacing the engine and turbos but they can't tell me what happened.

Sorry to hear of your troubles.

Can you post a copy of the service write-up and invoice from the dealer’s service department? That will often document the specific codes, diagnostic procedures, and remedies applied in the technical language that Ford mechanics and engineers use to communicate. Someone here like @Ducati1098 might be able to read that and provide more insight. (Please redact any personal info before posting.)

 

[wjtinfwb]

Truck is a 2023. I bought it used/certified at a Ford dealer in January with 35k miles and have taken it on several road trips without issue. Oil was changed at about 40k miles. About 100 miles from home on the most recent, a big orange wrench appeared on the display for a few seconds. There was no chime or scary alert message so I assumed it was a maintenance reminder. When I stopped for gas, I checked the app and saw that it was for "Powertrain Malfunction/Reduced Power" and instructed me to contact an authorized dealer as soon as possible. When I started driving again, I did notice that the power was reduced (no boost) and continued home for another 50 miles. It was Saturday night so I made an appointment to bring it in first thing Monday. I did not drive it Sunday but when I started it Monday to go to the dealer, it sounded rough and rattley. On the way, I got a momentary low oil pressure warning when I let off the gas but the measurement screen still showed 30+psi if I was on the gas so I continued to the dealer.
When the dealer finally got to it, they told me there was only about 1 quart of sludge in the oil pan and the engine was toast.
Ford covered the repair, replacing the engine and turbos but they can't tell me what happened. I KNOW 6+ quarts of oil were put in it at 40k miles and the dealer said there were no signs that it leaked out so what causes an engine to consume 5 quarts of oil in 5000 miles?
I'm taking it back this week because it feels underpowered. Normal driving seems fine but acceleration seems weak and it only shows 10 psi boost at WOT.
Has anyone else dealt with something similar?
Looking for opinions on what happened and advice if dealer claims "nothing wrong".
Thanks!

My VW Rabbit started drinking oil, so much that I kept 2 quarts with me to add at every fuel stop. The Rabbit only held 4 qts. so 2 quarts was half the crankcase. No smoke visible and no external leaks. Turned out to be the valve guide seals were defective and oil was getting sucked into the combustion chamber. Maybe the previous owner neglected the oil changes, the valve guides took the brunt of poor lubrication and when the motor expired all that was left is the "sludge" in the oil pan? Definitely an odd malfunction

 

[Tim Smith]

Your member info says Raptor. Is that the truck we’re talking about? I thought the 3.0 was a 7 qt fill.

Some older owners' manuals for the Bronco 2.7-liter V6 misstated the capacity at 7 quarts; later manuals corrected it to 6 quarts. If you have a Raptor 3-liter V6, then it is 7 quarts.

 

[heavyD]

Sludge usually requires time to build up. I wonder if the previous owner went too long without changing the oil.

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