Long post, sorry!
My "Engine" light came on and the Expedition started to misfire, I let off the gas and all seemed fine, the light went out and I got home (approximately 1/2 mile). The light came back on after I put it in drive, and it was missing real bad, and it smelled as if it was running really rich. I then shut it down and called Ford Roadside, the Expedition is 14 months old / 28,000 miles. Long story short, Ford told me that the #3 fuel injector was dumping fuel into the cylinder, and then they got a real loud clicking sound. Turns out the #3 piston rod bent from the cylinder being full of fuel (I saw the rod, and my engine totaly tore down) and was hitting the bottom of the cylinder.
My 1st question is has anybody else heard of this happening before?
Question #2, Ford tells me I get a re-manufactured engine, not new. Is this a typical action? I think I should get a new engine, not rebuild. Ford says they have a replace policy with new or re-manufactured quotient that give a new engine at a $5,000 cost of parts to replace vs a rebuild at a $3,500 cost of parts to be replaced. What is the difference between a new and remanufactured engine, and should I be fighting this?
Any and all help would be appreciated.
Thanks.

 

I do not believe an injector dumping excessive fuel is common, but does happen and is not unheard of, and has happened to all automakers in various vehicles. I did not understand by your post if you have to pay anything, I would believe it should all be covered under warrenty. As far as new engine vs. reman all Ford has to do is to make the truck function as it should. Techinically your motor was not new at 28k a reman engine would have all new of the most common wearing parts in it and should serve you fine. Putting a new engine in would be up to Ford and probably done as a goodwill gesture but not as a standard. I would talk to the zone rep or some news paper consumer advocate in your area, dealers hate bad press or problems and are quick to put them to rest. The "squeeky wheel gets the grease" good luck and save all your documents and keep details of conversations with dates and times in case you have problems later.

 

No, I do not have to pay anything, all costs are on Ford. My only concern was that a re-manufactured engine would have many used components installed, and hence have much less life expectancy. I was told by the local service rep that a re-manufactured engine is mostly new, but nobody is able to tell what parts are not new.

Thanks for your reply, I will take your advice.

 

Try the phone number near the end of this desription Good luck and don't sweat it I think it will work out and see if they will honor the 3 yr 36k warrenty on the reman.


Engines-Gasoline (Remanufactured)


Motorcraft® remanufactured gasoline engines offer a Total Value Package – a competitive GET 36 (36-month/36,000-mile) warranty for long blocks, excellent availability, quality and value for your money. They are the only remanufactured gasoline engines designed, engineered and recommended by Ford Motor Company. They’re manufactured with the same state-of-the-art testing methods and equipment used in building and testing new engines.

For more information on Remanufactured Gasoline Engines, Remanufactured Diesel Engines, or Remanufactured Transmission Assemblies call 800-392-7946

 

I wouldn't be too concerned about getting a remanu'd motor. The warranty is probably the same either way and any wear parts will be new anyways. That is one good thing about these modular engines, remanufacturing is not the same as you would think of in say, an old 5.0 engine. I'll bet the reman motor is 90% new parts, and the only real difference is that it didn't come off the assembly line with the "new" engines, which may not be a bad thing in itself.
As long as you get a warranty starting the day the new engine goes in, I wouldn't worry about it.

 

Schozee,
Thanks again for the reply. Part of my concern over the re-manufactured engine is that Ford tells me that this re-manufactured engine is waranted for only 12 months / 12000 miles, or the original warranty that came with the car, 3 years / 36000 miles, which ever occurs later. I currently have 28000 plus miles on the Expedition and I bought it new in December 2004. So, I will only get the 12000 miles which in my case equates to approximately 7 months of driving!
Ford told me that if I paid for the engine, then they would back it for 3 years / 36000 miles.

 

That part is BS. The warranty is for the engine, not the price you paid, or didn't pay for it. I would definately raise hell about that. Basically they are saying they have no conficence in their remanufactured engines, and they are not honoring the warranty on the one that crapped out on you alreay. I would say that very loudly in front of several potential customers on the sales floor until someone whisks you away to kiss your butt.

 

well a reman would ne my choice , they have less failure rate thena new.

block cut and sleeved
crank cut and micro polished
rods honed and checked
new rod bushings
cylinder heads 3 angle valve job with vacuum check
cams checked and polished
valve springs checked and installed

new

pistons
wrist pins
retainers
bearings
valves
oil pump
timing chain
tensioners

 

what they have told you is true and not unusual.

 

ford390gashog,
Thanks for the replys and reassuring data with regards to the remanufactured engine. I was also told that there is a real shortage of these engines, and to date it has been exactly 2 weeks that ford has had the vehicle and still have not received a replacement engine. Do you know if this is typical?
Thanks again.

 

well there is a shortage. expect about a 3 week time period. a new engine from the factory could take 6-8 weeks.

 

ford390gashog,

Thanks again. I guess I will just sit tight and wait for the remanufactured engine.
Can you tell me what transmission I have in this 2005 Expedition 5.4 3V? The owners manual gives service intervals for certain types and if I need to, I want to service the tranny, but I thought that I saw else where on this site that it is a sealed unit? Is this true? If so, is it normal to never change the tranny fluid?
Thanks in advance.

 

you should have the 4R75E trans. it gets flushed evey 30,000 miles with mercon v.

 

I have a friend who had worked for the ford plant warranty section years ago and I recall he mentioned it one time that he personally felt the remanufactured engines were better than the new ones.

 

aagitch,

Thanks for the reply. It has been almost 3 weeks since my Expedition has hit the Ford shop, and I still have no engine, still waiting for something to be delivered from Dearborn. That is apparantly how short Ford is on these 5.4 3V engines! Thursday I was told that now they will seek a "new" engine because that might be faster to get here. At this point, I really don't care which they send now! Though, what all have seemed to have said here is (as did you) that I would better served with a re-manufactured engine.
Thanks again.