Engine rattling and transmission

What else do I need to add to my description of problems to do a transmission rebuild and take care of common rear end problems while I am still under warranty for another 1k miles? This is what I can describe of what I experince... I received a new engine and turbos at 68k miles (oil change shop forgot to put in oil and seized engine while moving between bays) and new flex plate at 96k miles.
_____________

2018 Ford Expedition 4x4 edition. The last time I was in, we had an incomplete fix (new flex plate did not stop the engine rattle). As you may recall, I still have the loud rattle upon every start that lasts up to 10 minutes - sounds like pennies in a tin can. I also am experiencing some slipping in shifting - noted multiple times around 6th gear, eco mode, under load (up hill) and not (flat), where the shift misses, engine revs, there is a clunk of some sort and then I am grateful the car still moves. I have also experienced this slipping (no power, rev, clunk) in 3rd gear (ish) around town. I am now at 99,008 miles and need to get this in before I hit 100k.

Find a new dealer. These are easy issues to diagnose and fix. The CDF drum bushing is probably your trans issue. There is a TSB for it. As far as your rattling is concerned, your description is pretty vague so I can’t point you in the right direction. Could be 1 million different things based on what you’re telling me. I’ve never seen flex plate issues on these though.

From what your saying that sounds like the waste gates flapping during warmup, which is normal.

Its the waste gate linkage rattling. My expy sounds like a shyt box at startup and when accelerating down the street because of it . Also check the exhaust clamps

Thank you. For the transmission, they are saying they are going to "tune it" or "reprogram it" or something like that... they are going to plug in something and drive it for 50 miles. They said a rebuild not warranted as transmission is not "buzzing" and no metal in fluid (though that was recently flushed). I'll ask them to check waste gate linkage.

RickDenverRealtor said:

Thank you. For the transmission, they are saying they are going to "tune it" or "reprogram it" or something like that... they are going to plug in something and drive it for 50 miles. They said a rebuild not warranted as transmission is not "buzzing" and no metal in fluid (though that was recently flushed). I'll ask them to check waste gate linkage.

Click to expand...

Regarding the wastegate noise, there is no fix for it and its normal wastegate noise which is what my dealer said

SyndicateZ said:

Regarding the wastegate noise, there is no fix for it and its normal wastegate noise which is what my dealer said

Click to expand...

Well that would surely stink... sounds awful - I'm embarrassed to turn on my car in front of clients, and it wasn't always there. Hoping they find something different.

Because I don't know what a wastegate is, I asked chatgpt.
___________________________________________________

To address the wastegate rattle issue in a 2018 Ford Expedition, it's essential to understand the cause and then explore the available fixes. The wastegate in a turbocharged engine helps regulate the engine's boost pressure by redirecting exhaust flow away from the turbocharger's turbine, controlling its speed. A rattle from this area can indicate a mechanical issue, which could range from a loose component to more complex turbocharger system problems.

Here are steps and considerations for addressing the issue:

1. **Diagnosis**: The first step is to accurately diagnose the source of the rattle. This can be done using diagnostic tools and techniques specific to turbocharged engines. A mechanic might perform a visual inspection, check for loose components, and use a diagnostic scanner to check for any error codes related to the turbocharger system.

2. **Tighten or Replace Loose Components**: If the rattle is due to loose hardware or connections around the wastegate or turbocharger, tightening or replacing these components may resolve the issue.

3. **Wastegate Actuator Adjustment**: If the actuator that controls the wastegate is improperly adjusted, it can lead to rattling noises. Adjusting the actuator to ensure it opens and closes the wastegate flap correctly may fix the issue.

4. **Wastegate Flap Wear**: Over time, the wastegate flap and seat can wear out, leading to a poor seal and rattling noise. If this is the case, replacing the wastegate or the entire turbocharger may be necessary.

5. **Aftermarket Solutions**: There are aftermarket solutions available, including upgraded wastegate actuators or brackets designed to reduce or eliminate rattle. These components are often more robust than the OEM parts and can offer a more permanent fix.

6. **Check for Technical Service Bulletins (TSBs)**: It’s wise to check if Ford has issued any Technical Service Bulletins (TSBs) or recalls related to the wastegate or turbocharger system for the 2018 Expedition. Manufacturers often release TSBs to inform dealerships and service centers about known issues and recommended fixes.

7. **Professional Help**: Given the complexity of turbocharged systems, it’s recommended to seek help from a professional mechanic or a dealership service center, especially one that specializes in Ford vehicles. They can offer a more detailed diagnosis and have access to specific parts and tools required for the repair.

Remember, addressing the wastegate rattle promptly is important not only for noise reduction but also to ensure the long-term health of your vehicle’s engine and turbocharger system. Ignoring the issue can lead to decreased performance and possibly more significant engine damage.

The dealer did a "relearn" of the transmission and say it's "fixed". They agree that the rattle is likely the wastegate. They are saying "normal" and "within normal operation". SO frustrating as it is so loud and lasts so long. This noise didn't use to be there, and the turbos only have 30k miles on them (new engine and turbos at 68k miles). Are others experiencing this? Any OEM fixes? Other ideas?

I want to drive my Expedition for another 100k miles... but can't stand this rattle.


______________
ChatGPT offers: Adjusting the electronic wastegate actuator on a 2018 Ford Expedition involves interfacing with the vehicle’s electronic control unit (ECU) to modify its operating parameters or to diagnose and rectify any issues causing malfunction, such as a rattle. This process generally requires specialized diagnostic tools and software, which can communicate with the vehicle’s onboard computer systems. Here’s an overview of the steps involved, bearing in mind that specific procedures can vary depending on the diagnostic equipment used and the exact nature of the problem.

### Preliminary Steps
1. **Safety First**: Ensure the vehicle is parked on a level surface, the engine is turned off, and the key is in the off position.
2. **Equipment Preparation**: Connect a compatible diagnostic tool to the vehicle's OBD-II port, usually located under the dashboard.

### Diagnostic Software Use
3. **Vehicle Identification**: Enter the necessary vehicle information into the diagnostic tool, such as the make, model, and year—2018 Ford Expedition in this case.
4. **Accessing the Turbocharger System**: Navigate through the diagnostic tool’s menu to select the turbocharger or wastegate actuator settings. This might be under engine performance, turbocharger control, or a similar section.
5. **Fault Codes**: Before making adjustments, check for any stored fault codes that might indicate issues with the wastegate actuator or related components. Clearing these codes without addressing the underlying problems can lead to recurrent issues.

### Adjusting the Actuator
6. **Adjustment Settings**: If the tool provides options for adjusting the wastegate actuator, such adjustments might involve changing the parameters that control the actuator's position at various engine speeds and loads. This is a delicate process; incorrect adjustments can negatively impact performance, fuel efficiency, and emissions.
7. **Testing**: After making adjustments, it’s crucial to test the vehicle to ensure that the changes have had the desired effect and have not introduced any new issues.

### Calibration (If Needed)
8. **Actuator Calibration**: Some vehicles may require the wastegate actuator to be recalibrated after adjustments. This process ensures that the actuator's operation is synchronized with the turbocharger and engine requirements.
9. **Final Testing**: Perform a comprehensive test, including a road test, to verify that the wastegate rattle is resolved and the vehicle performs as expected across a range of conditions.

### Professional Assistance
Due to the complexity and precision required in adjusting electronic wastegate actuators, it is strongly recommended to have these adjustments carried out by professionals at a dealership or an automotive repair shop specializing in turbocharged vehicles or Ford models. They will have the most up-to-date software, tools, and training to ensure the adjustments are made correctly and safely.

Attempting to adjust the electronic wastegate actuator without proper knowledge and tools can result in incorrect settings that may lead to poor performance, increased emissions, or even damage to the turbocharger and engine.

My wastegate rattle is loud at start from both driver & passenger side for a minute or so at cold starts especially. Makes me never want to buy another turbo vehicle again no matter the make