NHTSA Complaint #11676758 — 2018 FORD F-150

While driving to Sam’s Club (approximately 20 miles from home), my 2018 Ford F-150 3.5L EcoBoost began running very rough, and the check engine light came on. I had the vehicle scanned, and diagnostics confirmed that the cam phasers are failing — the exact issue I had replaced under warranty at approximately 59,000 miles. The vehicle now has just 88,000 miles, and this failure occurred in under 30,000 miles since the original repair. I have maintained this truck with extreme care. I only use Motorcraft parts and fluids, change the oil every 3,000 miles or sooner, and always use premium fuel. This is not a maintenance issue. This is a design or part failure that Ford has not properly resolved. When the phasers were replaced the first time, I was told there was no warranty on the replacement parts. That is unacceptable. A known failure being replaced with an equally defective part is not a resolution. Ford is aware of this issue — there are multiple TSBs (including TSB 21-2130 and 19-2208) and widespread complaints across owner forums — but they have taken no responsibility. I paid over $44,000 for this truck and should not be facing the same critical engine failure twice before 90k miles. The rough performance and sudden malfunction while driving posed a potential safety risk. I am submitting this complaint so NHTSA can investigate and hold Ford accountable. This seems like a common problem with this engine, and I do not understand why there has not been a recall or why Ford has not been forced to implement a permanent fix.