Hoping My Bronco isn't too broken

byronpete21

Aug 05, 2022

Have a 2.3 L Badlands with the 7 speed manual. Last week at around 550 miles on the odometer the engine suddenly started making a loud tapping noise. Sounded like a bad valve to me, the service manager tried to tell me it was most likely injector noise from the high pressure fuel injection system. Finally got word today that after a week of back and forth with the big wigs at Ford Corporate, they think it is a valve issue, and they are supposedly sending a special tool that will allow the service department here to check the valves.
My questions are as follows: Given the fact that the 2.3 L has been around for quite some time in several of Fords other cars and light trucks. How would a reasonable sized service department not have the tools to work on this motor? Are the valves on the Bronco engine special in some way? Are they just blowing smoke up my back side?
Appreciate any insight, mostly just venting. It is super frustrating to not have my brand new toy to play with especially after waiting so long to get it. Also having it in the shop before it is even due for its first oil change is not ideal.
Should have another update mid next week, I promise to post what I find in case anyone else finds the info useful.

Touron, BuckYeah

Last edited by a moderator: Aug 05, 2022

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Aug 05, 2022

Awwww man, that sucks and sorry to hear that you are having issues! Hopefully they get you back on the road quickly & efficiently. Good luck @byronpete21

- 2023 Raptor / Shadow Black / MGV (DOB 8/30/23)
- 2023 Heritage Limited Edition / Robin’s Egg Blue / 4dr / (stolen from my dealer 11/15/23)

Jakob1972, byronpete21

Aug 05, 2022

Huge bummer.

To answer you question, in most dealers and repair shops… the technicians themselves own and provide their tools, they are not provided by the dealer. Any special diagnostic equipment would come from Ford and likely only provided on a temporary basis.

I’m actually super curious what this mysterious valve tester is, never heard of it. I’m assuming it is something that is going to analyze the VCT system, but… probably will never find out. Hopefully it’s something relatively minor and not a complete engine replacement.

2022 4dr Badlands, 2.3L Manual, Mid pkg
YouTube: youtube.com/@ragnarkon
Instagram: @ragnar.kon

Bschurr, Jakob1972

Aug 05, 2022

byronpete21
Have a 2.3 L Badlands with the 7 speed manual. Last week at around 550 miles on the odometer the engine suddenly started making a loud tapping noise. Sounded like a bad valve to me, the service manager tried to tell me it was most likely injector noise from the high pressure fuel injection system. Finally got word today that after a week of back and forth with the big wigs at Ford Corporate, they think it is a valve issue, and they are supposedly sending a special tool that will allow the service department here to check the valves.
My questions are as follows: Given the fact that the 2.3 L has been around for quite some time in several of Fords other cars and light trucks. How would a reasonable sized service department not have the tools to work on this motor? Are the valves on the Bronco engine special in some way? Are they just blowing smoke up my back side?
Appreciate any insight, mostly just venting. It is super frustrating to not have my brand new toy to play with especially after waiting so long to get it. Also having it in the shop before it is even due for its first oil change is not ideal.
Should have another update mid next week, I promise to post what I find in case anyone else finds the info useful.

Man that stinks. Better to find it now rather than after the warranty.

Bronco Nation 1100. Everglades, Desert Sand
Res: 7/30/20 ordered 1/22/21 reorder 10/15/21 changed to Everglades 3/9/22 schedule 8/29/22 bumped to 9/5; 9/7/22 blend, 9/9 Mods, 9/26/22 completed, 10/7 shipped, 11/3/22 delivery

radar3d, Bschurr

Aug 05, 2022

RagnarKon
Huge bummer.

To answer you question, in most dealers and repair shops… the technicians themselves own and provide their tools, they are not provided by the dealer. Any special diagnostic equipment would come from Ford and likely only provided on a temporary basis.

I’m actually super curious what this mysterious valve tester is, never heard of it. I’m assuming it is something that is going to analyze the VCT system, but… probably will never find out. Hopefully it’s something relatively minor and not a complete engine replacement.

Thanks for the info, that makes a little more sense of the whole situation. I too am curious and hoping I don't need a whole new engine. This is what I get for making plans to go to Moab next month.

Aug 05, 2022

Jakob1972
Man that stinks. Better to find it now rather than after the warranty.

I agree, hope it can be fixed quickly I have really enjoyed driving it so far.

Jakob1972

Aug 05, 2022

So @RagnarKon is mostly correct the technician supplies all the general tools they need and the dealership is supposed to have all the special tools required in fact in most cases ford just sends them and the dealership is required to buy them they really don't have a choice so they should have all the special tools unless the have been lost or broken and not replaced

tasker, Deano Bronc

Aug 23, 2022

Quick update,
Visited my bronco today at the dealership. Apparently the issue is with the valves. All of them were out of factory spec, and all of the actuators were loose. The loose tappets would explain the noise I was hearing. The question I have is why (other than a quality control issue) the tappets would be loose and all of the valves be out of adjustment on a brand new engine? No one seems to have an answer.
Currently waiting on parts to essentially replace all the valves and tappets to see if this fixes the problem. If not then it looks like maybe a new engine for my Bronco at 550 miles in. Have to say I thought buying the 2.3 would save me from valve problems, apparently not.
The only bright side is that it is dead in one of their service bays so every day it is not fixed is costing them money which will at least give them some motivation for getting it fixed.

Bronco 202?, Deano Bronc

Aug 23, 2022

byronpete21
Quick update,
Visited my bronco today at the dealership. Apparently the issue is with the valves. All of them were out of factory spec, and all of the actuators were loose. The loose tappets would explain the noise I was hearing. The question I have is why (other than a quality control issue) the tappets would be loose and all of the valves be out of adjustment on a brand new engine? No one seems to have an answer.
Currently waiting on parts to essentially replace all the valves and tappets to see if this fixes the problem. If not then it looks like maybe a new engine for my Bronco at 550 miles in. Have to say I thought buying the 2.3 would save me from valve problems, apparently not.
The only bright side is that it is dead in one of their service bays so every day it is not fixed is costing them money which will at least give them some motivation for getting it fixed.

Do you have a 2021 or 2022 model year and when did you take delivery?

Might also be good to document the engine data in engine bay (pics) in case it happens again with someone else.

The first 2021 2.3 broncos built have had very few, if any, engine issues. When everyone switched from 2.7 to 2.3 after reading all of the 2.7 horror stories Fall'21-Winter '22, the 2.3 demand increased while QC decreased. The 2.3s built between December '21-May '22 had some issues reported with the turbo wastegate not opening and a few other minor things.

Suggest switching to full synthetic oil when you hit 1500-2K miles.

We've had our 2021 2.3 MT BL for almost a year. Thankfully zero engine issues

2021Bronco☆2.3☆BL☆7MT☆4D☆A51☆SoftT☆ARRIVED 9/9/21☆SOLD 1/21/23☆NT Supports▪Consults▪Supply's Car Dealers, Vehicle Distributors, and Retail Customers Since 1992

Aug 23, 2022

These ffffffing engine plants must have let the gorillas handle the American Tourister again!
https://www.google.com/url?sa=t&rct...=5b1aRop-UbU&usg=AOvVaw1rvzKRrrDveySDiIyiF8LS

Deano Bronc, Speed Devil

Aug 23, 2022

#10

Best of luck getting her up and cruising again!
I have been sweating bullets with my 21 2.7L with 4400 miles on it after l heard of the valve problems, so this surprises me.

Aug 23, 2022

#11

cindylou
Best of luck getting her up and cruising again!
I have been sweating bullets with my 21 2.7L with 4400 miles on it after l heard of the valve problems, so this surprises me.

Thanks, hoping for the best. Feel like the trust is gone. Hope I can get the trust back.

Aug 23, 2022

#12

byronpete21
Quick update,
Visited my bronco today at the dealership. Apparently the issue is with the valves. All of them were out of factory spec, and all of the actuators were loose. The loose tappets would explain the noise I was hearing. The question I have is why (other than a quality control issue) the tappets would be loose and all of the valves be out of adjustment on a brand new engine? No one seems to have an answer.
Currently waiting on parts to essentially replace all the valves and tappets to see if this fixes the problem. If not then it looks like maybe a new engine for my Bronco at 550 miles in. Have to say I thought buying the 2.3 would save me from valve problems, apparently not.
The only bright side is that it is dead in one of their service bays so every day it is not fixed is costing them money which will at least give them some motivation for getting it fixed.

Good luck..... At least it went out early and its at a dealership. Could have been stuck somewhere way off the beaten path.

You probably already know some of the 2.7L engines had bad issues during the 21 model year, I guess there's a formal investigation with the NHTSB going on. ----> https://www.motortrend.com/news/2021-ford-bronco-2-7-liter-engine-valve-troubles/

A big square Lightening Blue FE with puffy tires.....and a CB antenna for good measure! ;-)

Aug 25, 2022

#13

I don’t know why and how Ford keeps fixing things that aren’t broken. They have screwed up the 3rd gen 5.0 coyote and the 2.7 eco. Modern versions of these engines have been out a long time and didn’t need fixing! Hope the geniuses that made the decisions to modify are the first to go in the 3000 layoffs.

“BCH BRNC“ BlkDia 2Dr/MIC/2.7/AT/Carbon Gray/Mid Pkg
Res:10/20, Orders: MY ‘21 04/21, MY ‘22 10/21, Prod 8/8, Del 8/29

J.bell

Sep 08, 2022

#14

It's now been 6 weeks at the dealership. Got a new update today. They replaced the valve train on my 2.3 motor with all new parts and re-assembled my engine. Apparently within about 5 minutes it broke again (i.e. started making the same valve train noise) It would now appear that I get to wait for a replacement engine from Ford. Really considering a Lemon law claim at this point. Super depressed because the 550 miles I had with my Bronco before it broke were super fun. Thanks for listening to my sorrows. Until the next update wishing all the very best.

Byron

TreBronco, J.bell

Sep 08, 2022

#15

byronpete21
It's now been 6 weeks at the dealership. Got a new update today. They replaced the valve train on my 2.3 motor with all new parts and re-assembled my engine. Apparently within about 5 minutes it broke again (i.e. started making the same valve train noise) It would now appear that I get to wait for a replacement engine from Ford. Really considering a Lemon law claim at this point. Super depressed because the 550 miles I had with my Bronco before it broke were super fun. Thanks for listening to my sorrows. Until the next update wishing all the very best.

Byron

ah man, that sucks. Hope they get it sorted out for you!

22 BB 4dr SAS 2.7 Mid Pkg Hot Pepper Red, Delivered 8/25
Previous 2019 F150 Ruby Red SCrew 3.5 Eco, XLT Sport/FX4 302A

byronpete21, Speed Devil

Sep 08, 2022

#16

TK1215
These ffffffing engine plants must have let the gorillas handle the American Tourister again!

2dr Badlands 2.3 Manual w/Mid, Rapid Red
My blog, Mfcomics.net, my stories: https://payhip.com/MFComics

DadChris44, byronpete21

Sep 08, 2022

#17

Hope the new engine works out for you Byron, what a damn shame about all this bullshit.

Could be worse, at least it should be all warrantied and everything being a fluke, not like it happened down the road where they could claim you did something

2dr Badlands 2.3 Manual w/Mid, Rapid Red
My blog, Mfcomics.net, my stories: https://payhip.com/MFComics

Sep 08, 2022

#18

Speed Devil
Hope the new engine works out for you Byron, what a damn shame about all this bullshit.

Could be worse, at least it should be all warrantied and everything being a fluke, not like it happened down the road where they could claim you did something

certainly grateful it is under warranty for sure. Hoping to leverage an extended warranty or some sort of service plan from Ford. The good news is I am not putting any miles on it, so I will have one of the lowest mileage Broncos out there for sure.

Speed Devil

Sep 15, 2022

#19

Update today, Ford wants them to rebuild the head again with some new parts they are sending. Not sure how this will solve the problem since that is pretty much what they did last week. Was hoping Ford would just send them a new engine so I could get back to driving my new car I waited 2 years to get. It has now been with the dealership since the end of June. Hoping maybe I will have it back for a Christmas present.

Deano Bronc, ChickasawNDN

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