Ford Store in Morgan Hill, worked with me to fix botched job
Kevin and Art did a great job of handling me when I came in pissed off that a local repair shop called Grant's Garage had completely botched an injector cup replacement job on my 2001 Powerstroke Diesel Excursion. They made sure their most experienced diesel tech handled the job (I am sorry I don't remember his name), and at my request, called me once or twice when they had the issues that were left behind by the other shop exposed, so I could take pictures and see for myself that indeed, one of the newly installed cups was leaking because they had cracked it during install. Not only that, they found all the injectors had been installed without being torqued down--which causes blow-by, and that injector #8, a special injector, was in the wrong cylinder.
Initially, I did not even get a quote from the Ford Store for the job, because all the PSD and Excursion forums online talked of the horrors of $3-4K spent to have this job done, and the fact the Ford dealerships still pull the heads to do a job that can now be done with the engine intact with a new special tool. Grants offered to do the job for $1500 with the new special tool. After Grant's screwed up, my quote from the Ford Store to do the job included the new special tool, and was only $500 or so higher than Grant's Garage. Not bad for a dealership. They had adjusted the quote to reflect the time they could save with the new tool--and not because I asked. Not all dealerships would do that. They might still charge the big money because the extra time they save and charge for, is just gravy. BMW dealers do that all the time.
I was especially impressed when we discussed other jobs I might want to have done while they are in there, and when Kevin and I both independently looked up how much new injectors were, he literally called me up and said: "hey if they are working now, you might want to hold off. At around $350 each, and for 8, the price for parts would be close to $2800." But he did advise that we change out the glow-plugs, which are about as cheap as spark plugs. There was no record at Ford of them being done and the Excursion had 164K miles on it. Good call. The truck starts easier in the mornings and does not do the occasional smoking it would do when cold.
It's been a couple of weeks since the Ford Store's repair and my nightmare dealing with cracked injector cups leaking diesel fuel into my coolant, me spending a weekend trying to flush it out after the job was done wrong, seems over.
One comment I can make: the final flush the Ford Store did to try to remove the remaining fuel from the coolant system, should be done with the thermostat out. I still found a good amount of remaining fuel in the "de-gas" coolant tank that popped up a couple of days later. The thermostat barely opens in cold weather, and can take some time to dump the engine's contents into the degas tank so you can see it. Also, it takes some long drives with the heat turned all the way up to get the valves on the TWO heater cores the Excursion has, to open up and release any fuel they might have in them. Since I asked if they were going to remove the thermostat, and they said they would not, and the flush was not that expensive, I agreed. I knew I would need to pull the degas tank myself and clean it out once or twice.
2001 7.3L PSD Excursion Limited. 3.73 Final Drive. As of Feb, 2012, 163K miles and going strong.
-Diamond-Eye AL Steel 4" turbo-back
-Ford AIS intake
-Tony Wildman 6-position chip
-Tall guys take note: I installed later model F250-350 seats with adjustable headrests. Makes all the difference.
2003 BMW 760Li (the V12)
1999 Ford F250 V10 SD extended cab, 8' bed
former 300zx repair and modification shop owner. Nissan 300zx expert to the rest of the world, relative PSD newbie in this one.