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When was the truck apart last and who did it? That is a foreign object, it's real easy to drop something down the intake ports on the cylinder heads. My best guess is whoever had the intake manifold off (or EGR valve, ect) dropped a bolt down there. If the object finds the right spot it can get stuck in the intake manifold for a while, work it's way to the intake valves where it gets worn down until it's small enough to fit past the valves and into the cylinder. Ford is denying warranty coverage because a Ford part did not fail. You said the dealer fired the last tech for incompetence, well there you go. It's the dealer's responsibility (or whoever had it apart last) to fix it.
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I'm a mod friendly Ford Diesel Technician located in Sacramento California area.
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