2008 F250 6.4L - Engine Oil Overfilled, Heavy Water & Rust

[MangoMan]

Hi Guys,

New to the forum as I just found online while researching recent probs.

After 400 mile round trip (all highway, no pulling), engine started to vibrate just as I got home. I took it to nearest Ford dealer when Reduced Power came on. Water in Fuel light never came on.

Dealer performed diag and indicates: Verified concern. Found codes P088, P2296, P2291 and engine overfilled, check oil and found filled with fuel. Took fuel sample and found heavy water and rust. Also found P0299 for no boost found charge air cooler filled with fuel and oil mix. Turbos are inop due to lack of oil. Rust also found on fuel filters which are 'stamped' 2010 which this dealer thought to be very odd.

Background on Truck: Has 68k miles and have had all regular scheduled maintenance performed by another Ford dealer. 60k maintenance performed in April at 59.8k miles. Service notes indicate they changed the oil, replaced air and fuel filters, multi-point inspection and transmission service. Primary use is to and from the office which is only 2.5 miles each way.

Diagnosing dealer states they want to drop the fuel tank and inspect for contaminates for $1500. Possibility of replacing Hi-Pressure Pump ($1600), Fuel Pump ($1600) or as much as $12k if replacing entire fuel system.

Final note: Something similar occurred 18 months ago at 24k miles after Water in Fuel light came on followed by Fail Safe Warning. At that time, servicing dealer replaced the Fuel Tank, 1 Injector, DPF, Electric Fuel Pump.

Any advice or guidance would be most appreciated.

[senix]

Need to pull all of your service records, get in contact with Cory from Ford cust service on this site. Open up a service record.

It could be a couple of things here.

First seems like they are pointing to lack of maintance. You can stop that with records. Secondly seems like they are pointing to incorrect filters maybe...again if a ford dealer did it that is there problem.

Then there is the fuel issue. Perhaps the first time they did not do what was fully required or...you have an insurance claim because of bad fuel.

Best to start talking with your insurance and with whomever you get your fuel from.

[MangoMan]

Thank you Senix. I definitely have all my service records and will reach out to Corey on the site. Will keep posting with updates as they develop.

[FordCustomerService]

Originally Posted by senix

Need to pull all of your service records, get in contact with Cory from Ford cust service on this site...

I appreciate the shout-out, senix.

Originally Posted by MangoMan

Thank you Senix. I definitely have all my service records and will reach out to Corey on the site. Will keep posting with updates as they develop.

MangoMan,

Welcome to the forum! I have a busy inbox, so please expect a reply within a day or two from when you send it.

Cory

[MangoMan]

Thanks Cory. Just sent you a PM and look forward to hearing back from you.

[senix]

Originally Posted by MangoMan

Thanks Cory. Just sent you a PM and look forward to hearing back from you.

did you include your VIN?

[MangoMan]

Good question. VIN is 1FTSW21R48EB*****

[FordCustomerService]

Originally Posted by senix

did you include your VIN?

Thanks again for the support, senix.

Originally Posted by MangoMan

Good question. VIN is...

MangoMan,

I suggest editing your post so your VIN isn’t public (it could be considered private). I’ll reply within the next few days.

Cory

[senix]

Originally Posted by FordCustomerService

Thanks again for the support, senix.


MangoMan,

I suggest editing your post so your VIN isn’t public (it could be considered private). I’ll reply within the next few days.

Cory

Thanks Cory for stepping in and trying to ensure that the serviceing dealer has all the info to make the best of the situation for this guy.

[FordCustomerService]

Originally Posted by MangoMan

Thanks Cory. Just sent you a PM and look forward to hearing back from you.

MangoMan,

I arranged for you to get a call before the end of the day today.

Originally Posted by senix

Thanks Cory for stepping in and trying to ensure that the serviceing dealer has all the info to make the best of the situation for this guy.

You got it, senix.

Cory

[MangoMan]

I spoke with Senetha at Ford Corporate yesterday. She's going to speak with my servicing dealer's Service Manager and call me back next week.

I'll post another update next week.

Thanks again for the assistance.

[MangoMan]

Just got off the phone again with Senetha at Ford Corporate. The OEM is declining to do any kind of warranty repair siting 'Fuel Contamination'. She could not / would not answer the following questions. Any kind of guidance, assistance or additional information would be greatly appreciated.

1. Shouldn't the fuel filters catch / address contaminated fuel?
2. Shouldn't the engine have sensors indicating a problem with the fuel?
3. If I were to purchase another Ford Diesel, and if the filters and sensors are not capable of addressing this problem, how should I expect to avoid similar problems in the future?
4. How often does a situation like this occur with the Ford Turbo Diesel? Does it occur with the diesels made by other brands?
5. This vehicle comes off lease on Jan 3 2013. Why should I purchase another Ford Turbo Diesel if the problems above cannot be easily remedied?

She also would not provide me with the detailed findings used to make the determination - citing 'confidentiality'. Given that it is my truck and that it directly involves me, I find that unacceptable as well.

I am not a professional truck driver, nor do I drive a lot of miles. However, I've been a Ford customer since the early 90's and have a gooseneck horse trailer.

Sadly though, I cannot think of a good reason at this time to purchase / lease another, given the apparent outcome of this situation. Diesel engines have been around for many decades and are known to run for many hundreds of thousands of miles. It's one of the reasons we pay $6k+ for the upgrade. It strikes me as implausible that contaminated fuel is a new issue.

[senix]

Call your insurance company and put in a claim for bad fuel...contaminated fuel.

How can anyone outside of the refinery control the quality of fuel?

It happens accross all vehicle lines. VW has a real problem right now.

[MangoMan]

Thanks senix - you've been a big help and I appreciate your insight.

However, this does not appear to be an isolated incident. Prior to your reply here, I submitted a PDF of this thread to the National Vehicle Leasing Association. The first reply I received is from one of their Board Members:

"I had a customer with (2) 2008 F450 with the diesel engine, and they spent over $25k cumulative in fuel system related repairs in the first 90k between the two trucks.

Ford declined all repairs under warranty citing fuel and road contaminant issues.

2 identical trucks, with identical use, and mysteriously 2 identical responses from Ford.

Who do you think your lease customer comes to with a problem like this? Their experts, the independent leasing company. We have since lost this customer because of our inability to get Ford to “own up” to this problem.

Funny thing is that in all of this, Ford issued a TSB that said the fuel tank vent lines were too short and could be overcome with road contaminants. Ford still declined any repairs under warranty."

[senix]

Originally Posted by MangoMan

Thanks senix - you've been a big help and I appreciate your insight.

However, this does not appear to be an isolated incident. Prior to your reply here, I submitted a PDF of this thread to the National Vehicle Leasing Association. The first reply I received is from one of their Board Members:

Even the 6.7 has the same issues...even more so.

Anything with common rail High pressure fuel pumps...anything 2008 model year and up is possible for this.

does not make it right. An alternate way of lubrication is the answer.