[jevalek77]

I have had my truck back for almost a week and put about 300 miles on it. There has been no engine knocking from what I can tell. I just have a hard time believing that as bad as it was knocking when it went in that there wouldn't be some long term damage. I had asked the service manager several times what the compression readings were, as they told me it was tested. Since he could not get me the numbers I asked to have it re-checked. It went in yesterday and each cylinder was 375PSI, leaving the compression differential at 0%. The service manager also stated the specs were 350 - 400 PSI. Now I guess I'm supposed to just keep driving it until the missing screw shows up.

 

[jevalek77]

Sorry, but I'm confused. How would a screw get into the oil? The valve is in the exhaust gas re-circulation system, so where the valve screws are located oil pressure lubed? I think a much greater chance of either being sucked into the compression chamber and with any luck out the exhaust or has had happened into the pistons and valves doing damage?

I literally think about the lost crew in my engine every day! I was told from ford that it likely went out an exhaust valve. I doubt that seriously, I'm betting that screw is larger than the exhaust valve clearance. I've seen pictures of these screws pounded into the tops of pistons. Based on the engine knocking that I experienced that slowly went away on its own, I'm betting that's where mine is. Probably wont give me any issues until I'm pulling a fish house, 3 miles out onto a lake, temps tickling -40 F, 3am, with no cell phone service. Or the day after my warranty expires. I've had my compression checked twice since this happen and both came back at 375psi per cylinder, 0% variation, at least that's what I'm told. So unfortunate, I absolutely love this truck but its going to be untrustworthy until this screw turns up.

 

[jevalek77]

UPDATE - Since I got my truck back with the missing EGR screw somewhere in the engine it has driven rather well for roughly 600 miles. Well until last night as I was leaving my home I heard a pop from the engine bay. About a mile down the road I heard another even louder pop and some knocking. It threw a check engine light and went into limp mode, fortunately I was able to make it home about 10mph. Grabbed my wife's rig and went about my business. This morning I fully anticipated a long drive to work at 10mph. Well it started right up and is no longer in limp mode, it does still have the check engine light on and I have an appointment for 10am this morning. Hopefully they tell me the motor is junk so I can somehow get Ford to buy this POS back.

Ford says my issues were a turbo over pressure fault (p0234), and they found oasis bulletin on this issue. They reprogrammed the PCM and sent me on my way. The service manager told me it didn't have anything to do with the missing EGR screw that's lost in my engine. I personally find this very hard to believe as I heard the engine make a popping noise twice and then start knocking. It did run fine on the way home from the dealership.

 

[jevalek77]

Update on my disaster... I received a call back today from the Ford customer claims in regards to my buy back request. It was denied at this time, which didn't surprise me any. She said their technical service would be contacting the dealership with instructions for repairing my truck. This is where things when from bad to worse! I called the service manager shortly after for an update. He was told by Ford to install the new valve and check compression, if compression checks out good and no codes are thrown the recall is considered successfully complete??????? He also said they will assume the screw made it through the exhaust valves???? Keep in mid the engine was knocking something terrible when I brought it in, the mechanic that pulled it in the shop also confirmed it was knocking. The service manager said it sounded good today after they installed the new valve. They plan to drive the truck for the next few days to observe any abnormal behaviors before retuning it to me. WOW, I can not even believe they would release the truck without knowing where the missing screw was. Where do I go from here... Ask for a lifetime motor warranty?

UPDATE - Since I got my truck back with the missing EGR screw somewhere in the engine it has driven rather well for roughly 600 miles. Well until last night as I was leaving my home I heard a pop from the engine bay. About a mile down the road I heard another even louder pop and some knocking. It threw a check engine light and went into limp mode, fortunately I was able to make it home about 10mph. Grabbed my wife's rig and went about my business. This morning I fully anticipated a long drive to work at 10mph. Well it started right up and is no longer in limp mode, it does still have the check engine light on and I have an appointment for 10am this morning. Hopefully they tell me the motor is junk so I can somehow get Ford to buy this POS back.

 

[jevalek77]

A quick update on my truck. I received a call yesterday that my truck was ready to go. The dealership had put roughly 50 miles on it and reported that it ran good and it was no longer knocking. While they were driving it, I did get a notification from my Ford app that said the check engine light came on. When asked, they told me the tech forgot to hook up a few vacuum lines. When I picked the truck up I told them the only way I would except the truck was if they added a note to the work order that stated an EGR screw was lost in the engine. They agreed and I took the truck. I put roughly 40 miles on it last night and I felt like it wasn't making full power, but its hard to tell, I might just be paranoid. And a couple times I heard some rattling / knocking noises at low rpms when under load. At this point I'm driving down the road with the radio off, window down with my ear out the window. I'm calling the dealership this morning and requesting the "compression check" information they supposedly did.

 

[jevalek77]

Has anyone had any luck with Ford,. We can't get anyone to answer or call back. We have a customer care representative manager but she is like tracking down a unicorn.

I call Ford Customer Service pretty much every day. I have received a call back within 24 hours each time. So far they have...


Refused to work with me on a "buy back" option, always stating that it does not qualify at this time.


Refused my request for a ownership lifetime motor warranty.


Refused my request for a 100k motor warrant.


Offered me a 75k powertrain warranty, which I declined.


(All of this was when I was under the assumption that they would be rebuilding or replacing my motor.)

 

[jevalek77]

How far is your truck torn apart? Is the cab off like the other members? If they were able to repair the valve with minimal disassembly of the rest of the truck, I would be more inclined to accept the repair after a complete and thorough inspection. If they torn the entire cab off and the motor is completely out of the truck, I am sorry, but there is no way the truck is getting put back together like it was intended leaving the factory line. That is where I would draw the line and not be too happy about the situation.

It was only disassembled far enough to replace the valve. They bore scoped the intake looking for the missing screw and were unable to find it. Checked compression and are calling it good. Based on how loud it was knocking when I brought it in, I would bet that screw has been pounded into a piston or head.


Does anyone know if it is possible to bore scope the cylinders on these engines?

 

[jevalek77]

Update on my disaster... I received a call back today from the Ford customer claims in regards to my buy back request. It was denied at this time, which didn't surprise me any. She said their technical service would be contacting the dealership with instructions for repairing my truck. This is where things when from bad to worse! I called the service manager shortly after for an update. He was told by Ford to install the new valve and check compression, if compression checks out good and no codes are thrown the recall is considered successfully complete??????? He also said they will assume the screw made it through the exhaust valves???? Keep in mid the engine was knocking something terrible when I brought it in, the mechanic that pulled it in the shop also confirmed it was knocking. The service manager said it sounded good today after they installed the new valve. They plan to drive the truck for the next few days to observe any abnormal behaviors before retuning it to me. WOW, I can not even believe they would release the truck without knowing where the missing screw was. Where do I go from here... Ask for a lifetime motor warranty?

 

[jevalek77]

Attached are the pictures of my valve.

 

[jevalek77]

Well here's an update on my recall. After waiting for parts for the last 5 days finally they started on my truck today. NOT GOOD NEWS... One screw as I suspected was gone! The mechanic confirmed it was knocking when he pulled it in the shop. I'll try to attached some pictures. What's strange is it does appear the screws in my valve were welded on the heads? Now I guess I'm waiting on Fords instructions. And for the record I will be demanding a brand new truck.