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I had a injector stick open in my 2005 F-150. It flooded the cylinder with fuel and when I strated the engine it bent a rod in the engine. When I had the engine torn down there was noticeable damage to most all of the cylinders. This confirms the compression test done prior to tearing the engine down only 2 of the 8 cylinders had good compression. The Teflon coating is gone off of most of the pistons and some wear and scoring is present in the cylinder walls. The engine only has 65,000 miles. Has anyone else had this problem? Has anyone had sucess in getting Ford to repair their engine? Do you think this should fall into the extended warrenty that Ford has announced for injector problems (11 years or 120,000 miles)?
If I were you I'd put that engine back together and take it to the dealer with a copy of that letter. If your dealer can confirm that the injector caused the bent rod I'd say your covered under the extension. However, I could see that you might have an up hill battle on your hands.
Did it do major damage to the engine? Did they rebuild the engine or replace it?
Bent and cracked #5 rod, shattered the piston skirt, then the rod dug a nice groove in the block. It got a shortblock. Same deal though, injector stuck open and hydrolocked the engine. All the other cylinders looked ok IIRC.
I think proving the bent rod due to hydro-loc is a slam dunk it is the rest of the engine that I worry about.
Why do you assume it is fuel wash on the other cylinders that caused the scuffing and wearing of the teflon coating? If they do decide to take care of the engine for the scuffing, be prepared with maintnance receipts. You need to prove that you kept up with it. Might not matter anyway though. Have you taken the rod and piston out yet? Check for any gouging or chunks of the cyl missing low in the bore. Any deep gouges or pieces missing and you'll need a new shortblock anyways. If no damage like this, they might cheap out and just replace the rod and piston on the one hole, if they do anything at all.
The engine has used oil since it was new 1 quart every 1500 to 2000 miles. This was documented several times by the dealership but Ford never wanted to do anything about it. I guess this could also have something to do with the wear. I always kept the oil within acceptable range and had it changed every 5000 miles. The fuel wash I got from talking to a service manager at a local dealership. He said that this is a possibility.
I haven't heard anything on the injector extended warranty yet, but if it does exist then I don't see why they wouldn't take care of the engine. Just provide as much proof as you can about maintnance records. If the dealer can't do anything for you, call ford. They might provide more satisfaction than the dealership can. Good luck, and let us know how it turns out.