Thoughts on this oil leak... Valve Cover Gasket?

[5280tunage]

So I was literally just getting ready to change out my spark plugs and coils, when I went to pull the engine cover off and found this mess. It only appears to be on the drivers side, the passenger side looks completely fine. Any thoughts? Is this likely a bad intake manifold gasket? It's pooling in the bolt hole just below the two gray hoses, above the filler neck so it's not like it's just leakage from pouring in fresh oil. The entire drivers side valve cover looks covered in the dirty goopy oil layer. If anything, i'm wondering if this is a left over issue from the phaser replacement I had a couple years ago.

Appreciate some thoughts, it is under warranty but now I'm thinking I shouldn't do the plugs and coils till after I have it looked at so they can't blame me for something.

Thanks in advance.

 

[Soliyou]

So I was literally just getting ready to change out my spark plugs and coils, when I went to pull the engine cover off and found this mess. It only appears to be on the drivers side, the passenger side looks completely fine. Any thoughts? Is this likely a bad intake manifold gasket? It's pooling in the bolt hole just below the two gray hoses, above the filler neck so it's not like it's just leakage from pouring in fresh oil. The entire drivers side valve cover looks covered in the dirty goopy oil layer. If anything, i'm wondering if this is a left over issue from the phaser replacement I had a couple years ago.

Appreciate some thoughts, it is under warranty but now I'm thinking I shouldn't do the plugs and coils till after I have it looked at so they can't blame me for something.

Thanks in advance.

This is a cracked valve cover. The plastic cover has a design flaw that causes it to crack. Ford fixed it with a modified part couple of years ago. Mine has just started to leak.

 

[5280tunage]

oh fantastic. So oil gets out, debris gets in. is there a particular place where it often cracks that I can check? Fun part is I'm sure I'll still have to pay my warranty deductible. is it both covers or just the drivers side?

Also, does anyone have a service bulletin or something I can reference?

At least it shows Tasca parts has like 500 of these in stock so I won't be without a truck for months.

 

[Soliyou]

It is a thin crack so I don’t think debris will get in. Only the driver’s side is affected (so far). I circled the area where it generally cracks.

 

[5280tunage]

that's where the majority of the oil pooling is too, so yeah, that's likely it. Thank you for the help. Love it when forums really help folks. Wish there was an SSM or something I could refer to. I bet they argue with me.

 

[keny01998]

I got oil burn smell because of valve cover gasket and the dealer replaced it under warranty 2 years ago. I had to bring it to an independent shop and they pointed it out because my useless Ford dealer couldn't duplicate the issue as always.

 

[5280tunage]

Luckily with the amount of residue and the fact that the oil is literally pooling on top of the cover, and the passenger side is clean as a bell, I think it's hard to argue. The biggest issue is now since I'm in the ESP, I'm guessing they will make me pay my deductible even though it's apparently a very well known issue 2016 and above.

 

[SyndicateZ]

Were the cam phasers replaced within the last year or so ? tech prolly damaged it when tightening back up too tight etc.

 

[Deadman]

They usually over tighten them when they do the cam phaser repair and crack the covers.

 

[5280tunage]

Were the cam phasers replaced within the last year or so ? tech prolly damaged it when tightening back up too tight etc.

unfortunately it's been more like 2.5 years since the phasers were done. the amount of oil covering the cover says it's been leaking a while. my issue is this could have easily started before 36k miles, i'm at 49k now.

 

[5280tunage]

They usually over tighten them when they do the cam phaser repair and crack the covers.

I blame the techs about 50% and the use of plastic for valve covers 50%. Aluminum properly stamped is just as light and definitely stronger. everyone knows that most plastics also break down over time with temperature fluctuations, caustic substances, etc.

 

[Benztech]

I had the same scenario. I did the plugs and coil first, and had no issues when I took it in for the leak repair under ESP.

 

[Scooter455]

Luckily with the amount of residue and the fact that the oil is literally pooling on top of the cover, and the passenger side is clean as a bell, I think it's hard to argue. The biggest issue is now since I'm in the ESP, I'm guessing they will make me pay my deductible even though it's apparently a very well known issue 2016 and above.

I have the same issue - The oil is puddled up on the groves in the top of the valve cover - Just sent pic to my service advisor. I actually complained about it right after they changed the phasers and they did nothing.

 

[5280tunage]

I was able to actually find the crack and take a good photo of it from a couple different angles. exactly right where several youtube videos say to look.

 

[Scooter455]

So I was literally just getting ready to change out my spark plugs and coils, when I went to pull the engine cover off and found this mess. It only appears to be on the drivers side, the passenger side looks completely fine. Any thoughts? Is this likely a bad intake manifold gasket? It's pooling in the bolt hole just below the two gray hoses, above the filler neck so it's not like it's just leakage from pouring in fresh oil. The entire drivers side valve cover looks covered in the dirty goopy oil layer. If anything, i'm wondering if this is a left over issue from the phaser replacement I had a couple years ago.

Appreciate some thoughts, it is under warranty but now I'm thinking I shouldn't do the plugs and coils till after I have it looked at so they can't blame me for something.

Thanks in advance.

I have the same identical issue

 

[5280tunage]

@Scooter455
So frustrating. Clearly a defect. Just out of curiosity, did you have your phasers done?

Several of the Youtube vids and some info from makuloco say two common things seem to be part of this, between 40 and 50k miles, and having the phasers replaced.

 

[5280tunage]

Good lord - so it's been a week, 7 phone calls and 3 voicemails, and still haven't gotten ahold of service manager at my usual dealership. I have only one decent one with 20 miles, it's hard to be positive about ford with build quality and the cusotmer interface to the company, their dealers.

 

[Fizzy]

So, mine is in for a transmission rebuild as we speak, and the sericve advisor called to let me know the tech also found the valve cover was leaking, and they need an extra day to replace it (under warranty luckily).

Is the replacement cover part redesigned so it won't happen again, or am I going to have to do this every few years?

 

[5280tunage]

So, mine is in for a transmission rebuild as we speak, and the sericve advisor called to let me know the tech also found the valve cover was leaking, and they need an extra day to replace it (under warranty luckily).

Is the replacement cover part redesigned so it won't happen again, or am I going to have to do this every few years?

It looked identical, supposedly it's all about the torque on the valve cover bolts and because it's plastic, if it's just a hair too much, crack. One tech also told me it's very common due to the hot/cold cycles, they weaken over time and if it's too tight, it will crack. I just don't understand why a valve cover is plastic. Aluminum wouldn't way that much more but could be easily produced and could be stronger. Or even if it was a combination, like make the mounting surface aluminum and the shell plastic. or put stainless steel sleeves in the holes that would prevent you from overtightening.

 

[Fizzy]

It looked identical, supposedly it's all about the torque on the valve cover bolts and because it's plastic, if it's just a hair too much, crack. One tech also told me it's very common due to the hot/cold cycles, they weaken over time and if it's too tight, it will crack. I just don't understand why a valve cover is plastic. Aluminum wouldn't way that much more but could be easily produced and could be stronger. Or even if it was a combination, like make the mounting surface aluminum and the shell plastic. or put stainless steel sleeves in the holes that would prevent you from overtightening.

Hmm, when it inevitably happens again I guess I'll look into some aluminum aftermarket covers, which also seem to be pretty rare.