3.5 EcoBoost Years to Avoid: Reliability & Common Problems

The Ford 3.5L EcoBoost engine has become a mainstay in Ford’s truck and SUV lineup, offering a compelling blend of power and fuel efficiency. However, not all EcoBoost engines are created equal. Some model years have proven more problematic than others, leaving owners facing costly repairs and frustrating downtime. If you’re considering purchasing a vehicle equipped with the 3.5L EcoBoost, it’s critical to know which years to avoid to minimize the risk of encountering these issues. This comprehensive guide will delve into the specific model years known for common problems, the nature of those problems, and what to look for when shopping for a used EcoBoost-powered vehicle. We aim to equip you with the knowledge to make an informed decision and avoid potential headaches down the road.

Understanding the 3.5L EcoBoost Engine

The 3.5L EcoBoost is a gasoline, direct-injection, twin-turbocharged V6 engine first introduced by Ford in 2009. It was designed to deliver the power of a V8 while maintaining the fuel economy of a V6. Over the years, the 3.5L EcoBoost has undergone several revisions and updates, leading to variations in performance and reliability. Understanding these changes is crucial in identifying the problematic years.

Key technologies in the 3.5L EcoBoost include:

Direct Injection: Fuel is injected directly into the combustion chamber, improving efficiency and power.
Twin Turbochargers: Two turbochargers provide increased airflow to the engine, boosting horsepower and torque.
Variable Cam Timing: Optimizes valve timing for improved performance and fuel economy across the RPM range.

These technologies, while beneficial, also add complexity to the engine, increasing the potential for failures. The early iterations of the 3.5L EcoBoost, in particular, were prone to certain issues that have been largely addressed in later versions.

Which 3.5 EcoBoost Years Should You Avoid?

While the 3.5L EcoBoost is generally a reliable engine, certain model years have a higher incidence of reported problems. Based on owner reports, repair data, and expert opinions, the following years are generally considered the ones to avoid:

2011-2013: These early model years are notorious for timing chain issues, turbocharger failures, and condensation buildup in the intercooler.
2017: While not as problematic as the earlier years, the 2017 model year has been reported to have issues with the fuel injectors and occasional turbocharger problems.

It’s important to note that not all engines from these years will experience problems. However, the higher incidence of reported issues makes them a higher-risk choice compared to later model years.

Common Problems in 3.5L EcoBoost Engines (2011-2013)

The 2011-2013 3.5L EcoBoost engines are particularly susceptible to the following issues:

Timing Chain Issues: The timing chain can stretch over time, leading to poor engine performance, rough idling, and eventually, engine damage. Symptoms include a rattling noise on startup and a check engine light.
Turbocharger Failure: The turbochargers can fail due to oil starvation or excessive heat. Symptoms include a loss of power, unusual noises from the engine, and excessive smoke.
Intercooler Condensation: Condensation can build up in the intercooler, leading to a misfire or stumble, especially during acceleration. This is often referred to as the “EcoBoost shudder.”
Spark Plug Issues: These engines can be sensitive to spark plug condition and gap. Improperly maintained or worn spark plugs can cause misfires and reduced performance.
Wastegate Actuator Problems: The wastegate actuator controls the boost pressure of the turbochargers. A faulty actuator can lead to overboost or underboost conditions, affecting engine performance.

Specific Issues with the 2017 3.5L EcoBoost

The 2017 3.5L EcoBoost engine, while generally more reliable than the earlier versions, has been known to experience these problems:

Fuel Injector Failure: Fuel injectors can fail, leading to poor engine performance, rough idling, and a check engine light.
Turbocharger Problems: Some 2017 models have experienced turbocharger issues, although less frequently than the 2011-2013 models.

Why These Years? Investigating the Root Causes

Several factors contributed to the higher failure rates in the earlier 3.5L EcoBoost engines. These include:

Design Flaws: The initial design of the timing chain system was prone to stretching.
Material Quality: Some components, such as the turbocharger bearings, may have been made with lower-quality materials.
Software Calibration: The engine control unit (ECU) calibration may not have been optimal, leading to excessive stress on certain components.
Lack of Updates: The early models did not benefit from the numerous updates and improvements that were implemented in later years.

Ford has addressed many of these issues in subsequent versions of the 3.5L EcoBoost engine. However, the legacy of these early problems continues to affect the perceived reliability of the engine as a whole.

Which Vehicles Use the Problematic 3.5L EcoBoost?

The 3.5L EcoBoost engine was used in a variety of Ford and Lincoln vehicles. The problematic years (2011-2013 and 2017) were primarily found in the following models:

Ford F-150: The most common application of the 3.5L EcoBoost engine.
Ford Explorer: Used in the Explorer starting in 2013.
Ford Flex: Offered as an option in the Flex.
Lincoln MKS: Used in the MKS sedan.
Lincoln MKT: Found in the MKT crossover.
Lincoln Navigator: Used in the Navigator SUV.

When considering a used vehicle from these model years, it’s crucial to thoroughly inspect the engine and check for any signs of the aforementioned problems.

What to Look for When Buying a Used 3.5L EcoBoost

If you’re considering purchasing a used vehicle with a 3.5L EcoBoost engine, especially from the potentially problematic years, take these steps:

Check the Vehicle History Report: Look for any evidence of engine repairs or maintenance.
Listen for Unusual Noises: Pay attention to any rattling, knocking, or whistling sounds coming from the engine, especially on startup and during acceleration.
Inspect the Engine for Leaks: Check for any signs of oil leaks around the turbochargers, valve covers, and other engine components.
Check the Spark Plugs: Inspect the spark plugs for wear and tear. Replace them if necessary.
Test Drive the Vehicle: Pay attention to engine performance, acceleration, and any signs of misfires or stumbles.
Have a Mechanic Inspect the Vehicle: A professional mechanic can perform a thorough inspection and identify any potential problems.

By taking these precautions, you can reduce the risk of buying a vehicle with a problematic 3.5L EcoBoost engine.

The Evolution of the 3.5L EcoBoost: Improvements and Updates

Ford has made significant improvements to the 3.5L EcoBoost engine since its introduction. Later model years (2018 and newer) are generally considered more reliable due to these updates:

Redesigned Timing Chain: The timing chain system has been redesigned to address the stretching issues found in earlier models.
Improved Turbochargers: The turbochargers have been upgraded with improved bearings and materials.
Revised ECU Calibration: The ECU calibration has been optimized to reduce stress on engine components.
Port Fuel Injection Addition: Some later models feature both direct and port fuel injection, helping to reduce carbon buildup on the intake valves.

These improvements have significantly improved the reliability of the 3.5L EcoBoost engine. If you’re concerned about potential problems, consider purchasing a newer model year.

Alternatives to the 3.5L EcoBoost

If you’re hesitant about the 3.5L EcoBoost engine, there are other engine options available in Ford and Lincoln vehicles. These include:

2.7L EcoBoost: A smaller, more fuel-efficient EcoBoost engine that offers good performance.
5.0L V8: A naturally aspirated V8 engine that provides plenty of power and a classic V8 sound.

Consider these alternatives if reliability is your top priority.

Making an Informed Decision: Balancing Power and Reliability

The 3.5L EcoBoost engine offers a compelling combination of power and fuel efficiency. However, it’s essential to be aware of the potential problems associated with certain model years. By doing your research, inspecting the vehicle thoroughly, and considering later model years, you can make an informed decision and enjoy the benefits of the 3.5L EcoBoost engine without the risk of costly repairs. Ford continuously refines its engine technology, addressing past shortcomings and improving overall reliability. Knowing which years saw fewer issues empowers buyers to confidently choose a vehicle that meets their needs and budget.