It should be quite obvious to all of us that poor relationships with suppliers has it's pitfalls.

 

In this case since most reports of AC failure occurred after some miles, how would spot check reveal the issue unless they run a sample for days on a rolling basis? No vehicle manufacturer has that kind of process for QC for supplier parts. It is true that we pay ford to manage the supply chain but that's also why the external (assuming this is not a Ford owned subsidiary) suppliers exist, they make the specific part that is more cost effective as a specialized producer that sells to multiple manufacturers rather than having each manufacturer be in charge of the production to a granular level. We saw something along the same lines with the Dana m256 fiasco, where the manufacturer deviated from initial designs and changed the axle tube design without notifying Ford.

I mean, perhaps with some manufacturers there is a process to drive an assembled vehicle for 1000 or 2000 miles after assembly out of every batch to make sure everything is working, but I am not sure if the SDs have that kind of sampling. I know for a fact Toyota has a process in place in plants like Tahara plant where each Lexus GX and one out of every so many 4Runner get drive a certain number of miles but I don't think even they go above 50 miles or so.

Considering how many of the 24 MY trucks haven't been sold yet, I think this is a case where the consumers' first hand experience was the only way this issue could surface.

 

You first have to identify the root cause of these failures, then it will provide the path forwards on how to inspect or test these compressors for product compliance. Fords QC department should have already identified the root cause with the supplier and should have already implemented a corrective action plan with the supplier to resolve the issue with new production and a QC method to screen out any potential defective WIP and existing inventory to prevent these defective compressors from reaching KTP or other final assembly plants.

 

Fords CEO Jim Farley acknowledged Ford has too many quality problems and hired Josh Halliburton in 2022 to drive quality improvement and reduce defects at Ford Motor Company. Farley went on record stating it will take Ford several years to fix its' quality problems. Based on where Fords quality is at today, I would have to say this has been an epic failure.

Ford CEO Farley tells retired engineers fixing quality will 'take several years' - Autoblog

 

Whoa whoa whoa... where did "without notifying Ford" come from?

That conjecture is so improbable, it can be confidently dismissed out of hand as an imagined assumption without basis.

Ford is Dana's largest customer (based on Dana's Annual Report). Dana builds axles to Ford's request, requirements, and specifications, and produces various models and versions of Dana axles exclusively for Ford, supplying these versions only to Ford, by contractual agreement.

I wouldn't have been able to obtain the diagram describing Dana's light-weighting method of reducing un-sprung weight by selectively reducing axle tube thickness, if Ford was not an approving participant in that product plan. Dana did not blindside Ford. More likely, both Dana and Ford were together, as engineering partners, blindsided by customer's real world experiences that neither computer simulation nor proving ground testing could discover or replicate.

Although given the proof of hindsight, it seems like a no brainer to not have the axle tube thinned out at the leaf spring seat. That is where most axle tubing failures show up, including prior Dana axle housings that Dana supplied exclusively to Ford... housings that were 1 mm thinner than otherwise equivalent housings (except for weldment locations for shocks and bars) that Dana supplied to other customers. The Ford destined housings cracked... on top of the axle tube, right at the spring seat. Repeat threepeat.

And the axle that had tube deformation / collapsing problem at the spring seat in 2022 was the M-275 rear axle, not the M-256 front axle.

Regardless of the particulars, Ford is ultimately responsible to the consumer for the failure of a part that Ford incorporates into the production of trucks, no matter who the supplier is.

When the infamous 6.0L engine failed under warranty, customers had to take their trucks to the Ford dealer for remedy, and would be turned away from any International dealer, despite International supplying the engine to Ford.

We can't go to the air conditioning compressor supplier for remedy either. Nor can we substitute a different AC compressor, without voiding the warranty on the entire HVAC system, and perhaps also risk voiding the warranty on the FEAD system as well.

If Ford wasn't responsible, Ford would not be paying the $3,600 service bill that a member in this thread reported that their servicing dealer submitted for reimbursement to replace the AC compressor and related items needed to make the vehicle whole again.

 

You can mark my truck as repaired. Compressor replaced and I was able to pick it up yesterday. It spent 22 days at the dealership. Good luck to everyone else still waiting. Looks like repairs are picking up in pace.

 

Update: Just got my truck back from the dealer getting my AC fixed. They replaced the AC Compressor, AC Condenser, and evaporator expansion valve. Dropped the truck off for diagnosis July 8th had do pick it up for a campingtrip. AC Compressor came in to the dealer on July 18th, dropped truck back off for repairs on July 22nd and picked up from AC repairs July 25th. It's not too hot here today but AC is working currently.

 

update from jojodancer

egine 6.7L HO
build date feb 28
failed on 5/15
resolution:
AC clutch
compressor
expansion valve
lines (metal shavings found)
picked up 7/23

 

• Model, Trim & Engine.....2024 F350 XLT Tremor. 7.3
• Manufacture Date... 03/24
• Odometer miles & Date when it failed... 817 miles. failed 7/19/24. Took delivery of truck 7/12/24. EXACTLY 7 days after delivery.
• fix date and resolution.... No repair yet. Diagnosed 7/23 with faulty compressor. Dealership advised compressor on backorder. Estimate 10 days to repair

 

Picked mine up on the 22nd. So far it is still blowing cold air.

 

I emailed Ford a couple of weeks ago. Didn't get an immediate reply, but was pleasantly surprised to get a phone call from their corporate offices Thursday. They were letting me know that my AC parts were being shipped out to my local dealership. Will have my truck in the shop next Friday.

 

Just picked up the truck, blowing cord air. So we can update me to resolved as of 7/26/24.

 

Take mine off the list. It is fixed as of today.

 

I wish that Ford would send out a Standardized repair for this issue. I have a feeling those of us who only got a compressor replacement are going to have to return to the dealer for a second attempt. Time will tell! Enjoying the cold air and being able to use my new truck!

 

10 months later, still blowing super cold air. Even on 100-degree days, it's keeping the truck cold.