As mentioned before, one of the exhaust cams broke. Interestingly, these cams are put together in more than one piece with splined inserts and the splines wore down and so part of the cam was not turning. So of course valves were hanging down banging on the pistons so all three pistons on that side, plus rods and the complete head assembly need to be replaced. Also, unburned fuel made its way to the catalytic converter and destroyed that as well.
Ford is not willing to replace the engine but has instructed the dealer to make the repairs. Obviously this does not sit well with me and so I've opened up a case with Ford customer care… more to come......
I am speechless that they're still talking rebuild instead of replacement. I would think that they'll end up spending a LOT more money covering labor hours to go that route than all new hardware would cost...
I mean, to R&R the long block, oil cooler/lines, turbos, it couldn't be more than 12-15 hours... but to tear down the motor, verify specs on everything from the bores to the main journals, vat the block to get all the crap out of it, etc... talk about a full time gig. Most dealerships don't even have the necessary tools to do it right... and on top of that, they
still have to pay the labor to R&R everything. I really think that you're on the right track in pushing for a replacement... because there's no way they'd do a rebuild correctly... they'd lose their ass in terms of time/$$.