Engine replaced at less than 20k miles

I have had my ST since September 2019 and for the most part I would say it has been problem free. The only issues I really had were a stuck window switch which was replaced, a cracked cat converter which was replaced under a recall and driver heated seat stopped working in which heating element was replaced.

Long story short, I was getting a bad smell from the exhaust on a cold start and scheduled a visit with the dealer. They needed to run diagnostics since the cat converter was already replaced in Feb 2023. About a week later they said the cam phasers were bad and had to be replaced and that it was a big job (30 hours I believe they said) but it was covered under warranty. Fast forward to six weeks later and I get a call from them stating they replaced the engine with a new one..I was like what? The tech was like "Yep, the cam phasers were bad but after we replaced it, the O2 sensor threw a code and eventually the engine just had to be replaced and that they got a new one from Ford and did what was needed". Not that I mind having a brand new engine but I was shocked that a smell from the exhaust led to this outcome. Part of me thinks the tech(s) messed up the repair.

I was contemplating selling the ST before this issue but now I am thinking it might be a good idea to keep it given that it has a new engine. I would say it is driving much better than before. Prior to the work, it was starting to feel sluggish which I was told was due to the bad cam phasers.

Anyway, not sure if anyone had a similar experience but thought I'd share because I would have never expected this outcome with such low miles. In a way I am glad I am still bone stock so they could not try to blame a tune for the issue. But the thought of getting a tune in the near future has definitely crossed my mind

Glad Ford did the right thing, and took care of you.

Way back in the day I bought a new Chevy Blazer with the new Vortec V6 motor. First year model, had a funny sound at about 1500 miles and took it to the dealer. Got it back the next day and still not right. Took it back to the dealer for the day. Got a call a few hours later, and said Chevrolet wants the motor back for R&D. They air freighted a new motor to install. After they put in the new motor, never had a problem. But Chevy really wanted that motor back.

Wow, ain't that something but it's nice when the right thing is done.

All in all, I really like the ST and I am glad Ford allowed the engine replacement. Unfortunately, I just did a cold start and the rotten smell is still there so will need to call the dealership tomorrow. I am thinking they just need to replace the cats.

I had to replace my engine at 34k miles. It was for a different reason, but Ford owned it and replaced it under warranty. a 90-day nightmare, but I was ultimately taken care of. more details on this site if you're interested.

I have 47,300 miles since December 2019, so far the engine is fine. I had the left catalytic converter replaced at 3 years and the fuel pump and battery replaced the first year and a half. I can't believe you have less than half my mileage and your car is 3 months older than mine!

@hbalek Covid and work from home significantly reduced my mileage. I’m about 19,700 now. Time for some road trips lol.


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So I spoke to the service department today and they recommend going through 2-3 tanks of gas and see if problem persists. They also said I should use a different gas or gas station as my gas had looked “dirty”. Not sure what that’s about but they suggested BP as an alternative.

Still love the ST though! Can’t wait to get it tuned.


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My engine was replaced at 10k for phasers.

Oh wow. Yea they told me mine were seized and they could not remove them.

Well..it seems it has to go back to dealer. After backing out the driveway and shifting into Drive, not even 20 ft in, it started vibrating vigorously and would not switch gears. I pulled over, shut it off for a bit and turned it back on but same issue. Vibrates excessively when shifting to R or D and struggles to move. Check engine light is on so going to pull the code to see what I am dealing with. I did just notice a drip underneath which appears to be oil. I am thinking oil leak or transmission leak after the engine was replaced. I've only had it back about 2 weeks and the only driving was taking kids to school.

Glad it happened right in front of our house and did not leave us stranded. Time for the 2025 lol.

Is there a service bulletin for the underlying issue? It's strange that the replacement motor would have a problem as well.

I just ran the codes and got the following. Also just noticed a leak underneath - looks like oil or transmission fluid. Dipstick showed a low level so could be oil.

P0345 - Camshaft Position Sensor A Circuit Bank 2
P0390 - Camshaft Position Sensor B Circuit Bank 2
P0349 - Camshaft Position Sensor A Circuit Intermittent Bank 2
P0394 - Camshaft Position Sensor B Circuit Intermittent Bank 2
P0304 - Cylinder 4 Misfire detected
P0305 - Cylinder 5 misfire detected
P0306 - Cylinder 6 misfire detected
P0300 - Random/Multiple Cylinder Misfire detected
P0496 - Evaporative Emission System High Purge Flow

The ford app also shows electrical fault and erratic signals with wiring from the engine timing sensors. Hopefully these are all easy fixes. Will need to get it towed to the dealer unless they come get it themselves.

I bought a brand new Ford Ranger STX back in 1996 with the 4-liter, V6. Within 20K miles the wrist pins in the pistons started to seize and the pistons were making a slapping sound. Ford replaced the engine under warranty.

In 2016 I had a Fusion Titanium with the 2.0 liter turbo that I bought brand new. I kept having waste gate & turbo codes popping up over & over. At one point the dealer said the top end of the motor needed replacing which is what they did under warranty. Within 2-months of that repair it began misfiring and acting up again. I took it back to the dealer and the next fix was to replace the entire engine which they did under warranty. They said within a few weeks of mine having the issues it did, they had (3) others with the same problem. I never found out the root cause. I ordered a 2018 Fusion Sport and traded in the 16' after that. I still have my Fusion Sport and it has 58K miles on it now and it has been a great car.

I should be getting mine back tomorrow. Not 100% sure what happened with the new engine damage wise but they said there was barely any oil in the engine. I’m guessing they never filled it with enough oil or it all leaked out while driving. I did see a small puddle of oil in my driveway but def not 5-6 qts worth and the only driving I did was taking kids to school.
Also, I find it odd the oil light didn’t come on if it was low on oil.

So I still have not gotten my ST back and really starting to miss it lol. I've been without it for about three months but happy that Ford and the dealer are doing the right thing. For now, the Edge loaner is filling the gap.

Last I heard the short block had to be replaced or rebuilt but now I’m told it’s the long block.

I’m expecting it to drive like it’s brand new when I do get it back so kind of excited about that. I also have an upcoming road trip from Ny to Fl coming up in April and hoping it makes it

Did your problems start with cam phaser noise on start up? My ‘23 with less than 2k miles on it is at ford now .. cam phasers are ordered and should be replaced in the next week or two. I’m wondering how many other ExST’s are having the known “Ford Cam Phaser” issues.

I originally took it in back in December for a bad smell from the exhaust on a cold start. They had already replaced the cats under a recall so they started looking into the cam phasers as the cause. They couldn’t get them out as they were seized which led to a new engine.
I never noticed the noise on startup as I usually remote start it and working from home, it barely gets driven otherwise.