RLXXI

NO amount of blow by is acceptable.
.

PerryB

The combination of excessive blow-by AND oil consumption makes me think its been seriously overheated at some point, and as a result the rings have lost tension. As several people have mentioned, a compression test is in order. Not only should you be looking at cylinder to cylinder variation, but you need to know the specification for the base number as well. For example, if the spec. is 150 and you have 105 across the board, it would pass from a variation/power balance standpoint yet still fail the baseline test.

I would certainly check the PCV (positive crankcase ventilation) valve, but I don't think it would account for the oil consumption, unless the oil is being externally pushed out past seals/gaskets in which case you'd see it in the form of an oily mess. If its burning that much oil in the cylinders you should be seeing it in the form of a black sooty tailpipe. Good luck.

F150Torqued

WELL...??? I would normally agree, and not to be argumentative or politically correct, but that would actually be in a perfect world. The crankcase is (supposed to be) sealed, including the oil filler cap, with exception of designed ventilation through the IM. If you totally seal the crankcase on a brand new engine - sooner or later the pressure in the crankcase would equal the average pressure of all eight cylinder's compression. That situation would certainly cause smoke (if only from hot circulating oil) to exit the open filler tube, like it would from a pan on the kitchen stove.

It seems the OP's challenge is determining whether the dealer's assessment is credible or biased to avoid a warranty claim. Checking ventilation is relatively easy - but the results are still subjective as to 'normal amount' of blow-by and a compression test from other than the dealer might be of no help on the warranty issue. Perhaps the best approach would be to "nail" the dealer's shoes to the floor so he can't back pedal - then pay him the $250 to do a compression test. Get a solid commitment (written if possible) what compression on a 40K mile 2011 5.0 is "within spec", then let them do it.

RLXXI

Blow by is caused by piston ring wear and/or not seating properly during break in (look up cylinder glazing), pcv gasses are normal and not considered blow by.

I've built my fair share of engines over the years and it is one of things that I do for a living.
.

PerryB

And make sure they do an actual pressure test, not just a power balance test. I've seen a lot of shops foist these off as "compression tests".

labtek

It seems that a few conclusions can be drawn from the posts so far...

-none of the posts should come as any surprise to the original poster since he was a service technician, albeit back in the 90's.

-a 40K engine is using an abnormal amount of oil- the oil has to be going somewhere

-dealer is using the standard "do not worry/they all do this/this is normal" rhetoric and threatens to charge $250.00 to discourage client from insisting on a critical diagnostic test

-it is not likely that the dealer will accept compression test results from anyone else other than themselves

To follow the principles of logic, you must therefore get the test done at the dealership, paying for it if you must and get a printed copy of the results and a receipt for your payment and if possible, the name of the mechanic who did the test.

You might keep a log of verbal/phone communications between yourself and the dealership, including dates, times, who you spoke to and any agreements entered into (if any)

Gather up any associated documented previous scheduled (and unscheduled) work done

Form a file of the aforementioned receipts, logs and any other things pertinent to this case

Here in my part of the planet, citizens have access to Small Claims court- if the compression test comes back as within specs, you could at least sue for your $250.00 back.

Or you could sue for that as well as a new engine.