Plastic (cracked) Valve Covers…Really Ford?

[19platty]

If I look at it today to see how bad it’s leaking, any specific spots on the valve cover area I should focus on?

Yep! Once you take your engine cover off. The LH valve cover (rh if looking at engine) there is a raised portion of the valve cover that the pcv hose connects to. It leaks around the molded portion on the valve cover. You cannot see the crack but that’s where they leak.

 

[BlakeMAX2019]

Master ford technician here. I would ask your dealer to contact Ford for financial assistance. Since you are barely out of powertrain it is very likely they will assist. Also, this is a very common issue with the left hand valve cover leaking around the pcv connection. I have seen them leak without ever being removed. So it has nothing to do with over torquing or removing the valve cover. The reason there seems to be a correlation is because so many of them leak, and so many of them need phasers. One didn’t cause the other. With that being said, IF it’s the VCT solenoid seals leaking on the valve cover, it is possible if they didn’t replace them, they could be leaking from removal.

If I look at it today to see how bad it’s leaking, any specific spots on the valve cover area I should focus on

If you have always serviced at ford there is a very good chance they may assist. I would definitely ask, you could also contact them directly if the dealer isn’t wanting to. I would ask about the vct seals being covered under service part warranty. Some of us take extreme pride in our work, but unfortunately some do not I would be embarrassed to perform a repair like some of the quality that I have seen from other techs.

thanks for that! It can’t hurt to ask right

 

[BlakeMAX2019]

Yep! Once you take your engine cover off. The LH valve cover (rh if looking at engine) there is a raised portion of the valve cover that the pcv hose connects to. It leaks around the molded portion on the valve cover. You cannot see the crack but that’s where they leak.

 

[BlakeMAX2019]

Yep! Once you take your engine cover off. The LH valve cover (rh if looking at engine) there is a raised portion of the valve cover that the pcv hose connects to. It leaks around the molded portion on the valve cover. You cannot see the crack but that’s where they leak.

I checked it out and yep you were right on… There is oil buildup all over both valve covers. I took a video but couldn’t attach it so here’s a screenshot.

 

[Dice Roll]

Does somebody make an old school metal one to go back with?

Could you do some sort of plastic welding or sealer around the pcv instead?

 

[5280tunage]

My drivers side had the hairline crack that even Makuloco showed in videos. The only reason i knew it was cracked is the little molding squares were filling with oil. Once I cleaned it a bit, I could easily find the hole near a stud hole. My easy guess is that it was tightened too much doing the phaser repair. Which again goes back to one of my biggest gripes about this stuff, like the Phaser fix, all this plastic stuff (including crap like the tranny pan) are essentially one time use. The heat/cold, and any removal and retightening is just asking for failures. It's so insanely frustrating that these things are lasting half as long as these insane payment plan durations so many need now to afford vehicles.

 

[Dice Roll]

Another thought I have is maybe the chronic overheating conditions the early trucks have are pushing these plastic bits to the limit and beyond.

 

[5280tunage]

Another thought I have is maybe the chronic overheating conditions the early trucks have are pushing these plastic bits to the limit and beyond.

it's possible, plastic just isn't as thermally resilient as metals. Everything expands and contracts, plastic in general (yes, I know that NASA has built insane plastics) isn't as forgiving. I think all of it combined means they just shouldn't be plastic, to try and save $5 per unit on 60+k vehicles.

 

[BlakeMAX2019]

My drivers side had the hairline crack that even Makuloco showed in videos. The only reason i knew it was cracked is the little molding squares were filling with oil. Once I cleaned it a bit, I could easily find the hole near a stud hole. My easy guess is that it was tightened too much doing the phaser repair. Which again goes back to one of my biggest gripes about this stuff, like the Phaser fix, all this plastic stuff (including crap like the tranny pan) are essentially one time use. The heat/cold, and any removal and retightening is just asking for failures. It's so insanely frustrating that these things are lasting half as long as these insane payment plan durations so many need now to afford vehicles.

Thanks for that insight, never thought of the one time use but it makes sense! Luckily the trans blew under warranty along with the rear end and cam phasers. The Y connect heater hose failed at 45kmi and now this at 57kmi. I know every make has issues but i have a 2006 Toyota 245kmi of heavy use hauling 5 kids around and have had none of these problems, I haven’t even changed a hose on it as they’re still in good shape! We love the MAX in many ways but it falls way short in quality.

 

[BlakeMAX2019]

If you have always serviced at ford there is a very good chance they may assist. I would definitely ask, you could also contact them directly if the dealer isn’t wanting to. I would ask about the vct seals being covered under service part warranty. Some of us take extreme pride in our work, but unfortunately some do not I would be embarrassed to perform a repair like some of the quality that I have seen from other techs.

So I contacted Fords Customer Service and have a case #. I should know by Wednesday if they are going to assist. They were very helpful and it sounded promising but who knows, we’ll see!

 

[5280tunage]

So I contacted Fords Customer Service and have a case #. I should know by Wednesday if they are going to assist. They were very helpful and it sounded promising but who knows, we’ll see!

Good luck, my only real experience with ford customer service lasted for over 9 months and almost resulted in a buyback. Kind of glad it didn't because I probably would have bought a Yukon and would now be faced with an engine recall, although I sometimes wish the phaser issue would escalate to becoming a full blown recall, not just a service bulletin. Folks can't be doing 3-4 phaser replacements over the course of a 150-200k mile lfe.

 

[Calidad]

Good luck, my only real experience with ford customer service lasted for over 9 months and almost resulted in a buyback. Kind of glad it didn't because I probably would have bought a Yukon and would now be faced with an engine recall, although I sometimes wish the phaser issue would escalate to becoming a full blown recall, not just a service bulletin. Folks can't be doing 3-4 phaser replacements over the course of a 150-200k mile lfe.

The recall vs quietly fixing if they get brought in and the dealer is open to loosing $ on the job thing has been a huge issue in the US Auto business since “dealers” were 3rd party businesses.

Not one “dealer” today wants warranty work. Its a loss of shop revenue over the $850 thermostat swaps, $2000 50,000 mile dealer service package of an oil change and car wash..

The dirtiest business today in the US is the Auto Group business Lithia, Auto Nation etc. They manipulate tech pay for entire regions, they manipulate perception of product availability, they manipulate regional pricing. They manipulate parts costs and shop costs for entire regions.

Any lawyer who grows a big enough pair could have the biggest monopoly lawsuit in American history going after Auto Groups.

 

[5280tunage]

The recall vs quietly fixing if they get brought in and the dealer is open to loosing $ on the job thing has been a huge issue in the US Auto business since “dealers” were 3rd party businesses.

Not one “dealer” today wants warranty work. Its a loss of shop revenue over the $850 thermostat swaps, $2000 50,000 mile dealer service package of an oil change and car wash..

The dirtiest business today in the US is the Auto Group business Lithia, Auto Nation etc. They manipulate tech pay for entire regions, they manipulate perception of product availability, they manipulate regional pricing. They manipulate parts costs and shop costs for entire regions.

Any lawyer who grows a big enough pair could have the biggest monopoly lawsuit in American history going after Auto Groups.

You know what, I couldn't agree more with you! I have absolutely refused to buy from an AutoNation shop. to the extent that i will pay more and drive hours away to avoid them, and i certainly won't use their shops. My favorite Jeep dealership in CO was one that i used literally for over 20 years. when they sold out to AutoNation, they dumped all the staff that mattered. The quality of service went to the crapper within weeks. I was in the process of getting a leaking radiator swapped, when they claimed they never found a leak and actually claimed they didn't diagnose it, wanting more diagnosis fees because the original diagnosis was done by the mom and pop owners, but the scheduled repair was to be done by AutoNation. I ended up driving to another Jeep dealer about an hour away a couple weeks later and they took care of everything.

Not to mention their sales people, oh you're just looking, let me go get our sales manager and nearly prevent you from leaving the dealership as they ask you about your grand parents. I actually used to have decent luck with a Lithia Jeep shop, but it's funny, there's an Auto Nation Ford within about 10 minutes from me, never been there for anything more than parts. I drive about 45 minutes away for all of my service needs.

 

[19platty]

So I contacted Fords Customer Service and have a case #. I should know by Wednesday if they are going to assist. They were very helpful and it sounded promising but who knows, we’ll see!

Let me know how it works out for you!

 

[Dice Roll]

Well my driver side is leaking now. Factory cam phasers. I smelled oil burning and thought somebody in traffic was losing their engine. Then I got out for gas and smelled it worse. Pulled the cover at home and sure enough it was puddled at the top in the front, and had run down the back and onto the exhaust. Goes in Tuesday.

****

 

[East-TN]

Well my driver side is leaking now. Factory cam phasers. I smelled oil burning and thought somebody in traffic was losing their engine. Then I got out for gas and smelled it worse. Pulled the cover at home and sure enough it was puddled at the top in the front, and had run down the back and onto the exhaust. Goes in Tuesday.

****

Keep us posted how your service experience goes.

 

[roard]

I feel your frustration—modern cars seem built to fail at this point.
Plastic valve covers cracking at 57k is just sad, especially on a vehicle like the MAX.
It’s like they know you’ll foot the bill for poor design just to keep it running.
Makes you question how “built tough” really applies anymore.

 

[Dice Roll]

Oh and I just rolled 45k a day or two before this started.

I’ve had 6 previous fords and Lincoln’s between me and my wife and this is first real failure I believe is not due to wear or age. Maybe that one axle seal at 90k on the 94 f150 was too soon, but that pales compared to a ****** valve cover.

I have a 69 440 GTX and it is still rockin the stock covers.

 

[Dice Roll]

Got a loaner due to using this dealer for everything always. Gave me a brand new escape to use. Just big enough to get by…for close to a week! Hope it gets done sooner. I simply can’t be without a car that hauls my people.

 

[Dice Roll]

Done along with trans tsb and will be back today!