Common Issues with 2018–Present Ford Expeditions and F150's

CHUCKS GARAGE • April 17, 2026

Recent Work Done Here at the Shop

The Customer Complaint

The scenario is almost always the same. A Ford Expedition owner comes in and describes a chattering, ticking, or rattling noise that occurs when starting the engine cold — typically first thing in the morning after the vehicle has been sitting for several hours. The noise lasts only a few seconds, then disappears as the engine warms up.

Typical Customer Complaint

"When I first start the vehicle in the morning with a cold engine, I hear a chattering noise that lasts for a few seconds. It's been happening for a while. No Check Engine Light."

The absence of a Check Engine Light is important context here. Many owners assume that if no warning light is on, there's no serious issue. That assumption is incorrect. The variable camshaft timing (VCT) system can be failing mechanically well before the vehicle's computer flags it with a fault code. Waiting only allows the condition to progress.

Vehicles Affected

Per Ford's Technical Service Bulletin, the following vehicle lines and build dates are involved:

2017–2020

Ford F-150
3.5L EcoBoost
Built on or before 11/30/2019

2018–2020

Ford Expedition
3.5L EcoBoost
Built on or before 11/30/2019

2018–2020

Lincoln Navigator
3.5L EcoBoost
Built on or before 11/30/2019

If your vehicle falls within these years and was built before November 30, 2019 — and you're hearing any version of this cold-start noise — you should have it diagnosed immediately by a qualified auto repair shop familiar with Ford's TSB procedures.

The Technical Service Bulletin (TSB 22-2200)

Ford TSB 22-2200 — Official Issue Statement

Some 2017–2020 F-150 and 2018–2020 Expedition/Navigator vehicles built on or before 30-Nov-2019 equipped with a 3.5L EcoBoost engine may exhibit a ticking/tapping or rattle type noise from the top front cover area of the engine on initial start-up after a cold soak of 6 hours or more that may last for 2–5 seconds. Some vehicles may also exhibit an intermittent condition with no auto restart during auto-start-stop operation, with or without DTC P164C present. This may be due to a worn variable camshaft timing (VCT) unit.

What This Means in Plain Language

The Variable Camshaft Timing (VCT) system controls when the engine's intake and exhaust valves open and close relative to the crankshaft's position. On the 3.5L EcoBoost, these units rely on oil pressure to maintain proper phaser position. When the VCT units wear out, they lose their ability to hold position during the low-oil-pressure window immediately after a cold start. The result is that audible rattle — metal components momentarily rattling until oil pressure builds.

Left unaddressed, worn VCT phasers can cause accelerated timing chain wear, chain guide damage, and eventually timing chain failure — which is a catastrophic engine event. This is why early diagnosis and repair matters significantly more than the noise alone suggests.

Technician Findings at Chuck's Garage

When our auto repair technicians at Chuck's Garage perform a diagnostic on a vehicle presenting this complaint, the process begins with confirming the cold-start rattle, identifying the noise origin at the front timing cover area, and cross-referencing against TSB 22-2200. In the cases we've handled, the diagnosis consistently confirms worn VCT units consistent with the bulletin.

What the Repair Involves

The Ford-prescribed repair for this condition is replacement of the VCT units — but because accessing the VCT phasers on the 3.5L EcoBoost requires removal of the front timing cover, the scope of work necessarily expands to include a complete timing system service. This is not upselling; it is the mechanically correct approach. Reassembling an engine with the old timing chains, tensioners, and guides after opening the front cover would be poor practice.

A complete timing kit service on the 3.5L EcoBoost involves replacement of the following components:

Components Replaced in a Full Timing / VCT Repair

Variable Camshaft Timing (VCT) Phasers
Engine Variable Valve Timing (VVT) Solenoids
Timing Chains (both banks)
Timing Chain Tensioners (multiple)
Timing Chain Guides
Camshaft Sprockets
Crankshaft Pulley Bolt
Timing Cover Seal
Camshaft Seals
Valve Cover Gaskets & Seals
Intake Manifold Gaskets
Water Pump & Gaskets
Coolant Thermostat & Housing Gasket
Engine Coolant Pipe Seal
Fuel Pump Gaskets
Crankshaft Seal
EGR Valve Gasket
All associated hardware and sealants

Because the water pump and coolant thermostat are accessed during this same repair, it is standard practice to service those components as well — preventing a return visit for components that were already exposed. The cooling system is also flushed and refilled with fresh coolant as part of this service.

Is Your Expedition Showing These Symptoms?

✓Cold-start rattle or chattering from the engine that lasts 2–5 seconds then stops✓Noise originates from the front of the engine / front cover area✓Noise occurs specifically after the vehicle has been sitting for 6+ hours✓Auto stop-start system stops working intermittently✓DTC P164C may or may not be present — its absence does not rule out the issue✓Vehicle is a 2018–2020 Expedition, 2017–2020 F-150, or 2018–2020 Navigator with a 3.5L EcoBoost

If two or more of these apply to your vehicle, bring it in. This is a documented issue with a clear service procedure — it should not be ignored or diagnosed over the phone. The longer worn VCT components operate, the more wear they transfer to the timing chains and guides downstream.

Why Bring Your Expedition to Chuck's Garage

As an established auto repair shop in Killeen, Chuck's Garage has the diagnostic tools, technical knowledge of Ford TSB procedures, and the experience with 3.5L EcoBoost timing systems to handle this repair correctly. We don't cut corners on timing work — this is one of the most consequential repairs an engine can undergo, and the quality of parts and execution directly determines how long the repair holds.

We also offer multiple financing options including Affirm, Snap Finance, Synchrony, and Klarna — because we understand that major repairs don't always come at a convenient time. Active military personnel receive a military discount, and our repairs come backed by a 5-year/unlimited-mileage warranty — one of the strongest coverage commitments you'll find at any auto repair facility in the Killeen area.

Chuck's Garage is a proud member of both the Greater Killeen Chamber of Commerce and the Harker Heights Chamber of Commerce. When you bring your vehicle to us, you're supporting a local business that's invested in this community.

If you are considering purchasing an Expedition or F-150 please allow us to perform a Pre-Purchase Inspection so you can buy with confidence.

Hear That Cold Start Rattle?

Don't wait for it to turn into something worse. Call or text Chuck's Garage in Killeen today. 254-554-5445

501 Liberty Street · Killeen, TX

Chuck's Garage

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Do These 4 Things in the First 60 Seconds Every July, the same thing happens at our auto repair shop in Killeen. Around 3 PM — school pickup time, Fort Cavazos shift change — the phone starts ringing. Another driver is watching the temperature needle climb into the red at a stoplight on Veterans Memorial. Central Texas heat is brutal on cooling systems. A weak radiator that survived all spring will quit on the first 104-degree afternoon. Here's what to do the moment it happens, what's really causing it, and how to tell a $40 fix from a $4,000 one. The First 60 Seconds · Turn the AC off and the heater on, full blast. Yes, in July. The heater core works like a second radiator. It pulls real heat off the engine while you get somewhere safe. · Pull over at the first safe spot. Not the next exit — the first parking lot or shoulder. Every minute in the red zone adds damage. · Shut the engine off and leave the radiator cap alone. That cap holds scalding coolant under pressure. We see burns from it every summer. Wait at least 30 minutes. · Call for a tow instead of “limping it home.” This is the expensive mistake. An engine that overheats once may be fine. An engine driven hot for fifteen minutes can warp its head. If we do the repair, the tow through our Bill's Towing partnership is free anyway. The 4 Usual Causes Low coolant or a slow leak The most common cause, and often the cheapest. Hoses, clamps, the radiator, or the water pump slowly lose coolant until the Killeen heat exposes it. If you're topping off coolant more than once a season, you don't have evaporation. You have a leak. Our cooling system service includes a pressure test that finds it. A stuck thermostat A $30 part that fails shut and blocks coolant from moving at all. The clue: the temperature spikes fast, even on short drives. It's one of the quickest repairs we do — and one of the fastest ways to ruin an engine if you ignore it. A dying water pump The pump is the heart of the cooling system, and Texas summers age pumps fast. Watch for a leak near the front-center of the engine, a whining noise, or temperature creep on the highway. Water pumps don't fail politely. They fail on I-14 in August. A dead radiator fan At highway speed, air flows through the radiator for free. At a stoplight, the electric fan does all the work. That's why so many Killeen cars only run hot in stop-and-go traffic. Fan motors, relays, and bug-caked radiator fins are the usual suspects. A weak cooling system also drags down your gas mileage — the U.S. Department of Energy's fuel economy site explains how an unhealthy engine costs you at the pump before any warning light comes on. Pros and Cons of Driving "Just a Little Hot" We hear it every week: “It only touches the red for a minute.” Let's be honest about that trade. Pros · You save money today. That's really the whole list. Skipping the visit protects this week's budget, and I understand why families do it. · Sometimes it truly is minor. One overheat from low coolant, caught fast, often does no lasting harm. Cons · You're gambling with the head gasket. Repeated heat warps aluminum heads and cooks gaskets. That turns a $150 thermostat job into a $2,500-plus repair. It's the most common “it ran fine yesterday” story we hear. · The breakdown picks the timing. Cooling systems don't fail in your driveway. They fail loaded with kids on the way to Belton. Add the tow, the missed work, the rental car. · The damage hides until it doesn't. Coolant leaking into a cylinder shows no symptom — until the morning the engine won't start. If your check engine light joins the party, stop guessing and get it scanned. · Resale takes the hit. Overheating history shows up in a pre-purchase inspection , and smart buyers walk away. Why Killeen Drivers Trust Chuck's Garage When the Needle Climbs Cooling repairs are daily work for our ASE-certified technicians. We pressure-test the system, check for combustion gases, scan for hot spots, and show you photos of what we find before touching a wrench. Chuck's Garage has been Killeen's trusted auto repair shop since 2010 — BBB A+ rated, with a 5-year, unlimited-mileage warranty on the work. Stranded? The tow is free with your repair. Tight budget in the middle of summer? We offer financing through Affirm, Snap, Synchrony, and Klarna, and we wrote honestly about when financing a repair is smart . Beat the Heat Before It Beats Your Engine A quick cooling system check in July prevents the head gasket bill in August. That's the whole math. Call Chuck's Garage at 254-554-5445 or stop by 501 Liberty St in Killeen. We'll test it, show you what we find, and get you back into the AC where you belong.