Have you tried end-running around the dealer and going to Ford corporate?

 

I went through a very similar experience back in 2018.
The 5.0 engine in my 2012 went kaput and warranty was replacing with a complete drop-in . The issue was that we went through 3 FORD crate engines before we got a good one. No idea where these rebuilds come from, but the QC was definitely lacking. At the time, supply was low so it took forever to find/order the replacement engine. The dealer was as frustrated as I was with the "quality" replacements parts. After the 2nd block, they even tried to do the rebuild in house, but Ford warranty said NO.
In these stupid covid times, I can't imagine what the wait time is going to be for parts and/or replacement engine.

What I learnt is FORD will not replace with a NEW engine on a 3 year old truck, you get a rebuilt unit. I would question why they want to "try" the top end first and if that don't work then move onto a complete engine. Maybe they have no engines available? For me, I chatted with the service manager, spoke with the techs that did the work, look at broken parts and new crate engines. Regardless, since it's all warranty, let them play with it and see what happens. Especially since you have a loaner.

FWIW, my truck was in the shop for 7 months. Not all bad, I drove various new loaners the entire time, which I used as my own, towing, hauling, etc.. Actually turned out to be great test drive to help choose my next vehicle.

 

I talked to the dealer today and the warranty company said to do the rebuild because they can’t get complete drop in engines right now. They said it would prolly still be a month to a month and a half to get the rebuild parts. I’m very grateful to have a loaner but I told the service advisor come spring they’ll need to give me a bigger SUV or a truck because the bronco won’t pull my 16 foot trailer loaded with 4 wheelers up to my cabin

 

I haven’t yet but I thought about that. I told the dealer how can they screw around this long and expect customers to be ok going without their trucks for months on end

 

I am very grateful to have a loaner and over the years Iv bought 13 trucks from this same dealer so they do their best to take care of me but I’ve never had an major issues like this. I did tell them if I don’t have my truck by spring they’ll need to give me either a bigger SUV like an expedition or another truck. The bronco is ok but it won’t handle my 16 foot trailer loaded with 4 wheelers going up and down mountains to go to my cabin. They did agree to give me something bigger if I don’t have my truck by spring

 

What is the extended warranty you bought? The Ford ESP plan? If so, that is a Ford Corporate extended warranty...not a 3rd party. I'm with others as this doesn't add up.

Your truck is less than 5 years old so the factory powertrain should be the primary means of coverage for this. This factory powertrain should also have covered the other repairs you've noted so either we don't have all the facts here or the dealer has royal screwed up how they've handled this.

However, either way...you've said they are covering it so at least there's nothing out of pocket for you other than loss of the vehicle.

If the block, cams, etc. are not damaged and they properly inspect and replace other parts that have been damaged as a result of this issue...a rebuild engine is not a bad thing. Rebuilt engines can be as good as knew if done properly. My gut tells me most dealers are not experts at rebuilding to like new.

 

If the dealer is getting reimbursed the hourly rate for the job and they have mechanics that can bolt stuff together how would this not be profitable for a service shop? Work is work, especially if the warranty pays the expected rates and estimated hours?

 

building an engine is a little more than tightening some bolts and slap parts together

 

I just talked to them and Ford engineers came out and told them to replace the head, phasers, camshafts, valves and springs. I told them that’s not going to fix the problem. The problem is no oil pressure to the top of the engine. Something is causing no oil pressure and it’s not going to be any of those parts. They said if this repair doesn’t fix the problem then the Ford engineers agreed that it needs a full engine replacement