This is massively long so if details aren't interesting skip this post. Of if you need an insomnia cure this might work for that too.

Not sure if anyone followed a previous post of mine regarding installation and break-in period or procedure for a Ford reman'd 5.4 in a 2005 E350 work van during September of 2018. The Ford engines arrive in a in a heavy duty enclosed shipping crate---its used for returning the core too. Ford includes new intake & exhaust gaskets, exhaust manifold studs and nuts, specified spark plugs installed, a new oil filter housing/adapter and filled with the proper oil too. The warranty is 3 years from purchase date and either 100K miles or unlimited---was told both things but it's not that important to me to nail this down--I don't anticipate driving much more than 60K miles during those three years.

Their support toll-free contact telephone number puts you in contact with friendly, helpful & knowledgeable technicians dedicated to dealing with drivetrain products. They asked for the VIN in order to register (for lack of a better word) and assign a case number for future reference should that ever be necessary. They do ask why the engine was replaced making sure IF it was related to any metal debris that could have been circulated in the engine and found its way to the intake it was imperative to replace---not clean---the intake too. Their reasoning being cleaning would not/could not remove metal bits embedded in the plastic intake, if such an intake were re-used those bits could work loose and cause valvetrain damage---in that event the warranty would be voided.

As the previous engine was replaced due very low oil pressure (hot idle @ eight (8) PSI, jumping upwards of 65 PSI just off idle) there was no need to change intakes Several trusted sources suggested that engine might last another few years, that I could add a concoction of 1 qt Lucas Oil Stabilizer along with 5 qts of 10-40 Rotella to see if that improved the frightfully low oil pressure. It had no effect once the engine reached operating temperature so the choice was to replace the engine on my schedule rather than have it come undone at some very inconvenient time while in service.

Unfortunately from the first crank up until the last few weeks there was a persistent and noticeable "miss" that resembled a bad COP or plug issue. No CEL, two separate full PCM scans for cylinder contribution by two different but very qualified former Ford techs showed nothing in the ignition or intake systems was at issue. Speaking with Ford Powertrain Tech Center they suggested performing a dry then wet compression test, that any Ford dealer would gladly welcome the chance to do warranty work OR I could have the original installation shop initiate a claim and they'd willing work with them on diagnostic/inspection procedures, the results thereof dictating what further action the warranty would allow.

I had that test done by another highly qualified shop, paid out of my own pocket a whopping $79. The numbers were as follows:

#1 dry: 150 wet: 165
#2 dry: 155 wet: 155
#3 dry: 155 wet: 160
#4 dry: 160 wet: 170
#5 dry: 160 wet: 165
#6 dry: 165 wet: 170
#7 dry: 160 wet: 170
#8 dry: 150 wet: 160

There was a bit of oil on plugs #3, 4 & 7 when removed, the engine had barely 1600 miles on it since installation.

Powertrain Warranty Tech Center didn't seem too concerned about those readings even after I pointed out #2 showed no change between dry & wet. At this point they "gently" said they wanted to talk this over with my choice of repair facilities: dealership or the original installing shop. The dealership part was NOT at all encouraging which I'll detail in the next post.

Continued

 

Continued............

Against better judgement I contact two different Ford dealerships to discuss this, to basically feel out how much BS I would face if going that route. One I buy all my Ford OEM parts from--including this engine---and the other a good 22 miles or so across town. First dealer told me IF a Ford dealership OR a Ford Technician had NOT installed this engine there was absolutely no warranty whatsoever. They added since it was installed in a 2005 E-Series van that made things worse because once they began all sorts of things would break off, be rusted blah blah blah. Immediately I called Powertrain Tech was told that info was completely wrong, they'd honor any qualified repair shop whether Ford had been involved or not.

(A few days later I contacted that dealership's service manager and discussed this with him. He was unaware of the warranty details, would investigate further and call me back--which he did same day. He essentially repeated the details of the warranty, told me this was completely new to him ???? HOWEVER since it was in a 2005 vehicle he declined to become involved. He also told me the "service writer" who was full of it no longer worked at that dealership, had move to another Ford dealer??? So much for dealership employees being factory trained--hell they're barely aware of their own brand's warranty policies.

Second dealership is under new management, current owner group somewhat well known for having a general great reputation, mostly with Honda since the 70's, now branching out to other brands. That conversation was far FAR more encouraging. The young service writer was well aware of these warranty issues, told me to drop it off (with appointment for quicker attention) and within a day or so they'd be back in contact. Another positive aspect was they said my max out-of-pocket would be about $120 (two hours diagnostic labor) IF the situation wasn't Ford warranty related. If it were and they were to do the repairs I'd have zero out-of-pocket.

I offered each dealership a short YouTube video of the very noticeable engine noise that was at the heart of my concerns. That was of no interest since they'd go by what they found and could not/would not even hazard a guess based on my video---fair enough, I do understand. This is that video:
The reaction of the first dealership mentioned highlights why I did NOT allow any of them to work on my van. I'd have been out at least $2K and lord knows what else had I foolishly let them do the diagnosis.. That dealership's attitude pissed me off but it wasn't completely unexpected or all that big a surprise.

Yesterday I sat down with the original installer (friend and a long-term customer of my glass biz) and called Powertrain Warranty Tech. They created a new case for them to use and bill against, asked a few questions, accepted the dry/wet compression test numbers and suggested valve covers on bank 1 be removed, components visually inspected. They did share most likely this was a head-related issue would probably send another reman'd head. I'm assuming intake and head gaskets will be included, if not I'll come out-of-pocket for those.

As of this writing I'm awaiting my shop's word on what they find. I did guarantee them to be paid even if its out of my pocket and I seek reimbursement myself. The shop did seem to be comfortable with Ford so that'll work in my favor.

Another huge reason I went with this shop is they'll keep me in the loop as things progress---I didn't think any of the dealerships would do so though.

I will update this as time goes on---if its interesting so much the better, if not I completely understand.

 

I've been contemplating going the route you have, as my van has just over a 100k, and am planning to do a big trip next year......but I may look at other potions now. Problem is there are no really knowing shops w/I 100 miles that I can find.

It just dashes any confidence in ordered rebuilds when hearing stories like this.

 

What would prompt you installing another engine with that low of mileage on the existing one? I have two other E250's with the same 5.4 motor that are still running quite strongly, both with over 275K miles on the clock; I'd not be the least bit concerned taking either of them across country.

Overall I'm quite pleased with the engine and for me relative ease of it being installed. I'm very fortunate knowing and having as customers quite a few talented and experienced mechanics. Were it not for the dismissive attitude of one single dealership there's nothing I regret. I will add my own desire to be wholly involved with the warranty repair has somewhat slowed progress--as I say to this point Ford has not refused or fought against warranting their product.

Certainly what comes after will determine if I remain happy with my engine replacement choice but I honestly don't feel I'm facing any shocks or surprises. After the initial conversation with Powertrain Warranty I'm far more comfortable with this whole thing than after the dealership conversations. Unfortunately Powertrain has no control or influence over the Ford dealers or their service functions..

If I didn't have my resources I might feel differently about using an ordered remanufactured engine. The flaw is a small problem but how its handled and dealt with will be how I gauge Ford's product. Honestly I don't think I would have done much better having this locally rebuilt piece-by-piece either in dollars or end result quality. Theoretically having this done in a production-line fashion yields more consistent results in the overall. One glitch such as mine shouldn't color the larger process.

But you'll have to make your own decisions based on your local options for work of this scope and nature.

 

Mine runs a bit rough at times for some reason. Uses oil all of a sudden at random times.
It's something on the passenger side bank. There are times I can smell oil in the exahust. I was told it needs new cats on that side. If I had the palace to do so, I could swap engines out myself.

 

That could be a number of things and without tearing into it tough to say or even guess. I'd do a bit of trouble shooting before diving in with a full engine swap.

I'm with you on this being fairly easy to do, apart from having a place and a few specialized tools that is. Otherwise its not overly complicated, just a lot of hard work.

Good luck with your project!

 

Zacly! Just a pain at times.

 

Okay a bit of an update on all this---my main goal here is talking through the concerns I'd have had my own self if I didn't have a lot of trustworthy mechanics to do this sort of thing for me.

The original installing shop initiated a warranty claim for me---after I'd become highly disillusioned with one stealership I'd contacted---they simply flat out lied about this and then said even if I paid out of my pocket they didn't want the work--afraid everything would break off etc. When reminded the engine had already been out a mere 3 months prior and they'd be working on nothing but the Ford reman'd engine they still pretty much refused.

Another dealership I contacted were very willing to dig into this, gave me an out-of-pocket fixed cost of $120. If they found a warranty issue I'd have zero dollars out. Sadly the first stealership was just five miles away, the second a good 22+.

Once my shop initiated the contact and claim with Ford's Powertrain Warranty center things have moved right along. The valve covers had to come off, anything looking out of place was to be reported. Nothing there, talk of replacing a head (or both) turned into pull the entire engine, There was nothing visible in the valve train or cam lobes or journals. Ford is almost begging the shop to find something they can use to justify sending another complete engine. That's great news as this doesn't sound like anything on the top end

The best part of this is just one warranty rep is dealing with this claim and he's calling the shop every few days for an update. I'm thinking within a few days of this post we'll have a better idea what's really wrong with the existing engine.

Dealing with the end of Ford's warranty program has been nothing but great----after dealing with the lies and BS of one dealership I'm glad to have chosen Ford!

I'll update this in case any one is interested in how this process works.

Thanks for looking in.

 

Thanks for the update. I'm glad it's going well.

 

Thank ya Sir!

 

Just updating this thread with info I've learned since installed the Ford reman'd engine and a subsequent warranty issue that cropped up.

-The dealership where the engine was purchased stays involved with any warranty issues so once a warranty claim is initiated its the parts department of that dealership that'll supply any needed parts and pay for labor incurred in the repair. That in and of itself isn't an issue as my dealership was easy enough to deal with overall, quickly fulfilling parts orders without delays or aggravations.

-If the engine is installed DIY you're forced to present the vehicle to a dealership where an inspection is preformed and repairs made according to their findings. Now this is where things get screwed up, at least in my case. My 2005 E350 is in great condition without any rust or such that would hinder "easy" replacement of anything engine-related. The original dealership simply refused to work on the van without seeing it, their claim it was too old to be an easy job. When it was pointed out the engine had already been installed less than 6 months prior, that all parts would be easily removed or replaced they didn't care, wouldn't even look at it regardless. (FWIW one of this dealership's recommended service writers told me flat out since the engine wasn't installed by their dealership OR another dealership OR a Ford "authorized & trained" technician working in another shop there was absolutely no warranty, any repairs would be borne by me. Not true but that's another topic....)

-Once a warranty claim is initiated there is a 30 day limit to file an invoice for all work performed making the necessary repairs. This info may or may not be conveyed when the claim is initiated but should you go this route be advised it needs to be considered. (I had an issue where the labor repair invoice was continually rejected by Ford as its submission had exceeded that limit by almost 90 days. The ONLY thing that "saved" me and the repair shop was Ford warranty had not informed me or the dealership parts department of this ticking clock and allowed an amended claim to be filed and paid. It should be noted this gaffe was caught by one of the warranty administrators who took charge and allowed the claim to be paid in full. For that reason I'm still very trusting in the Ford warranty division. )

On the issue of the lying dealership: I did find another dealer who would willingly take the van in for an inspection, telling me up front IF the needed repairs were a warranty claim I'd be out absolutely nothing money-wise. OTOH if that preliminary inspection didn't reveal anything the warranty would cover I'd be out a maximum of $120 labor time, that no repairs would be made or attempted without me being notified and authorizing any additional charges. They had no issues with the van's year or imagined fear of dealing with a rust bucket.

Even speaking with the service department "manager" he was mostly unapologetic about his now-former service writer who supplied the uninformed information my warranty no longer existed. (Oddly enough that service writer was no working in yet another Ford dealership?!?!?! None-the-less he was adamant the van was too old and they'd not be interested in doing any inspection or repair.

All is well so far and I've learned quite a bit, only hope to pass that info along to anyone else considering a Ford reman'd engine and DIY or non-dealership shop doing the work. I'm glad to answer any other questions should they arise.

 

I have been following your thread with interest. Besides wondering about the progress getting your repairs done, I am just to curious about the actual nature of the problem.
I am a long time car guy/professional mechanic/car builder restorer/ etc. As such I can't help but make a guess (even with insufficient information) and so here is mine.
My money is on the #2 intake valve. I'd say, in the course of a days work, the guy doing the assembly, had to answer a phone call or had to rush to the bathroom. In any case he skipped checking that valve or failed to lap it in.... I don't know but that head could have been dropped with the valve open and it took enough damage that it makes an imperfect seal. Not the kind of damage you would notice without testing.

I do hope that the final analysis is revealed, not just an executive decision to replace the heads, or the engine.

Anyway, CHEERS and good luck getting your van up to perfect.

 

Thanks for the good wishes!

Unfortunately there was no way to test, analyze or disassemble the head we replaced as it had to be returned intact in order to have the warranty claim paid. A close visual examination along with rotating the cam by hand didn't show any obvious signs of defect of damage. Your guess about it being the #2 cylinder is pretty much in line with my own idea as the noise heard in my video definitely seemed to come from that area.

One reason I wanted to update this thread is to alert others of the possible minor problems dealing with the warranty issues going through a Ford dealership. As I relate the claim was eventually paid with help from one of the Powertrain Warranty agents----he was absolutely one of the most helpful people I've ever dealt with in nearly any endeavor. He was more then technically competent and had a great knowledge of Ford's warranty policies and how to navigate that maze of craziness.

FWIW I have just over 10K miles on the engine since it was replaced and its doing okay. There is a small but noticeable vibration that resembles a bad plug or less-than-perfect COP but nothing shows up through a scanner or cylinder contribution test. No DTC's either---puzzling but dependable and driveable as is so for now it'll be left alone until or unless it acts up again.