Does a larger intercooler void your warranty?

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Dethred

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There is never any clear answer on this. The example I have, is the following:

Gen 5 Dodge Vipers have had about a 10% rod bearing failure rate. The Gen 5 cars also have a tune available that increases power by about 5%, but more importantly changes throttle response, removes downstream O2 sensor monitoring for emissions purposes, and removes things like skip shift.

When motors failed and had the tune, Dodge immediately voided the warranties for all the cars with the tune. The catch is, that the very man that headed the Viper Engine development team for 20 years tuned the car, and the tune was sold by the company that literally builds and supplies Dodge with the motors. Dodge still fought back.

A few owners decided to lawyer up, and before the cases even reached court, Dodge relented and covered the motors... the only stipulation being an NDA for each covered owner, to prevent other owners from learning about these motors being covered (yeah, F*CK Dodge). These aren't 2k differentials, or something small. We're talking $25,000 long blocks, plus a few thousand in labor. In this case, Dodge had no way to prove that the bearings were failing due to a slightly more aggressive tune, and already had attempted to address the bearing issues prior to the threatened lawsuits.

To this very day, Dodge is attempting to deny warranties for any aftermarket part installed on a car with a failed bearing, hoping that the owners don't find out about the successful disputes from other owners. Dodge has even acknowledged the bearing issues by releasing a recall that included an oil contamination test (of course literally every car passed it). An owner in Vegas recently had his claim denied, and a few months of fighting, a few letters from a lawyer, and some help from other owners later... his motor was replaced under warranty.

My long winded TL;DR point? If you have an aggressive tune making 100hp over stock and throw a rod, you're screwed if you can't hide the tune. If you throw a rod and only have a K&N drop in filter, it's worth fighting a warranty denial (Dodge tried voiding Hellcat blower warranty claims for K&N filters and had to give in). If you have an intake or intercooler and throw a rod? Fight it, because no honest engineer or mechanic can link the mod with the problem. If you have an intake, and your MAF or MAP sensor fails, Ford might get away with denying your claim.

Disclaimer: Yeah I bought the tune for my Viper even after hearing about the fight others had to go through, so that's my bias concerning mods.
 
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Dr.Duct_Mossburg

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I can assure you they have deeper pockets than anyone here.

This... Your best bet in a scenario is Ford not wanting the negative publicity. They will evaluate that into the claim. Either way, It's going to cost you more money to hire an attorney to go back and forth with them just to even pay for the repair.

I work for a big well-known brand. No one wants to be sued from a PR standpoint... but a common tactic is for the companies in-house attorney to talk with your attorney as much as possible. Your attorney is billing you by the hour - Every conversation they have with the companies attorney they turn around and typically call you about and then send you an email recap of. At $300-500 an hour depending on where you are and how good of an attorney you got... It gets very expensive, very fast.
 

smurfslayer

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My experience on both modded and stock vehicles is that it varies widely, and an honest shop with mechanics that are not automatons won’t dunk your warranty or attempt to deny coverage on a clearly unrelated issue. it helps to know where your service manager stands before hand, and helps to have a relationship with them. You don’t put them in a bind by showing up with the N20 hooked up and a hole through the block, expecting to take advantage, and they don’t go looking for a warranty denial on unrelated stuff. I’ve had mech. tell me take the car home, remove xxxxxx parts and bring the car back.

I protested, but this is <interrupts> trust me on this.
I got the message, did what he suggested and all was right in the world.

many years back, I was caning a Chevy, sort of racing a buddy with an obviously faster car. I missed the 3-4 shift, and boom. I later found out that I’d made an introduction for Mr. Valve to meet Mr. Piston.

I was going fast, definitely beyond any legal speed limit. Service Manager bluntly told me ‘you were definitely wide open and the computer showed you going *** mph’ ... car will be ready in a few days. covered, no problem. he asked what happened and I told him, I missed a shift while driving it pretty hard. That car was stock.

However, trouble doesn’t always happen close to home, with your home shop available. You have to use some judgment with mods if warranty is going to be a concern. A CAC probably isn’t implicating the transmission, transfer case, drive shaft, differential etc. Motor? doubtful unless something goes pretty wrong, but it would come down to what the shop decides. Likely, unless there is sensor data to prove it, I think it would be hard for an expert witness to honestly testify that your more efficient CAC caused an engine hard part failure or a host of other issues engine related. I’m not saying a manufacturer wouldn’t be able to get one, but, I would wager someone with a vehicle and aftermarket CAC could prevail in court if it came to that.

YMMV
 

nikhsub1

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To expand a little on what smurf is saying above, dealers WANT to warranty and fix your vehicles! They get paid good money for it by Ford. The trouble is usually LESS with the dealer and more with corporate when there is a very bad failure that an 'engineer' needs to come out and inspect. Like a rod bearing etc. Trust me, the dealer is hoping they can bill Ford $10k plus to install a new motor for you!
 
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