Cracked valve cover - common problem?

Cracked valve covers are another thing to watch on the 4th gen.

Should have known something would happen to my '18 expy after I mentioned a week or so ago that I haven't used my ESP yet.

Burning oil smell, found oil on driver side exhaust manifold, removed engine cover, traced to the valve cover. Internet searches revealed lots of 3.5 ecoboosts with cracked valve covers. This video pretty much sums it up: https://www.youtube.com/watch?v=pKk4K_M2ksY

Goes in next week for diagnosis at dealer, can't wait until they tell me covers are on backorder.

I've read that a couple other members here had them replaced (bobward757 and Deadman). Some folks have been waiting over 6 months for the part.

I wonder if my 2019 had this, last time I changed the oil I noticed there was an oil leak that started up high. I didn't look too deep into it at that time then it was totaled 3 days later so not a problem but in the quick glance the oil was coming from somewhere up high towards the middle.

Often stems from cam phaser mechanic screwing them up as well....

duneslider said:

I wonder if my 2019 had this, last time I changed the oil I noticed there was an oil leak that started up high. I didn't look too deep into it at that time then it was totaled 3 days later so not a problem but in the quick glance the oil was coming from somewhere up high towards the middle.

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Check valve cover gaskets. I had mine replaced under warranty after I constantly smelled burning from the cabin. Ford dealer was useless af and they couldn't duplicate it. I brought it to an independent shop and they pointed out the valve cover gaskets in 10 minutes. I had to bring it back with a note from the independent shop and Ford dealer finally agreed to replace new gaskets. I think the gaskets were messed up when they replaced cam phasers.

I had a burning oil smell after cam phaser repair, and it turned out to be an O-ring that seals a spark plug hole in the valve cover that got pinched during reassembly. Might just need a new perimeter gasket or O-rings for the spark plug holes.

For those of you who had valve cover gaskets replaced I am in the same boat. But the driver side valve cover is said to be on national back order. And my issue does coincide with the cam phaser repair.

Both sides were leaking. I was doing an oil change and find oil under the engine cover and had been smelling burnt coolant.

Just got it back last week but they only temp fixed the driver valve cover waiting on back ordered gasket.

bryz_expy said:

For those of you who had valve cover gaskets replaced I am in the same boat. But the driver side valve cover is said to be on national back order. And my issue does coincide with the cam phaser repair.

Both sides were leaking. I was doing an oil change and find oil under the engine cover and had been smelling burnt coolant.

Just got it back last week but they only temp fixed the driver valve cover waiting on back ordered gasket.

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Mine is leaking in the same exact place as yours. I can see a hairline fracture on my cover on the shoulder just below the bolt where the oil pools (right where your light is shining in the first pic). I did have my cam phasers replaced (~20k miles ago).

The valve covers are coveeed under warranty by a TSB. 5K on my new ones so far, dry and no smoke.

bobward757 said:

The valve covers are coveeed under warranty by a TSB. 5K on my new ones so far, dry and no smoke.

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Any chance you have a number for the TSB?

Dealer confirmed my cover is cracked and it would be at least two months to get the replacement part. Covered under my ESP and didn't mention a TSB. Maybe if I had the TSB I could save myself the ESP deductible.