Well it looks like it's my turn to be one of the few 6.7 engine failure negative stats. 2 weeks ago I was on my way to a race pulling a 36' enclosed car trailer. I had just traveled about 100 miles of interstate and had exited. Within a couple of miles of lower speed driving I noticed a slight flutter as I tipped in to the throttle. I lifted, checked the dash, no warnings or CEL so then I step back into the throttle. Yep, it was missing. I found a place to pull over within 1/2 mile of the problem starting and by the time I got pulled off the road it was knocking and squealing. I shut it down and called a buddy that was on the way to the same race. I keep a cheap code reader in the truck so I checked to find it did have a pending cylinder 2 contribution code. When my buddy arrived we unhooked the trailer and pushed the truck back into a parking spot. I called another buddy from back home that runs a wrecker service and let him know where the truck was, where I hid a valet key and where I wanted my truck delivered to. I was about 5 miles from the race and after considering giving up and going home I decided (with a little encouragement from my buddy) to go race. I'm glad I did but that's another story.
We are covered up with work at the shop so I didn't really get a chance to get into it right away. My 1st thought was a HPFP failure so I inspected the primary fuel filter & fuel rail pressure regulator and they were clean as a whistle. I scoped the cylinder and the piston looked like it might have been bumping the head so I dropped the oil pan to check for metal. Here's what I found.
I had an extended warranty Ford gave me because of on going emission problems that the local dealers couldn't fix. It would have covered this except it ran out the first part of April, of course. I called anyway and they let me know I'm on my own. Not complaining about that, I know the expiration date is just that.
I checked my options and considering the amount of metal in the pan I decided the most practical route was to order a Ford reman. short block. I started on it Friday after closing up and took advantage of a day off today to go pull it out and tear it down.
#2 rod had spun, #6 rod on the same journal is about ready to spin. #2 main is in bad shape. #5 & 7 rods look perfect as does #3 main. I can't see how this could be a lubrication or contamination problem because of the affected parts and where they lay out in the oil flow. This truck has just over 60,000 miles on it and of course has been well maintained and taken care of. Oil checked periodically, never ran low, never overheated. I do run a little fast on the highway but the truck isn't beat on. PM22A added every time it's fueled.
While tearing down I found at least 6 of the 8 mm head bolts so loose I could turn them in by hand. It makes me wonder what else was done wrong during the engine build. This truck was built in May of 2012 and I intentionally avoided buying an early build truck. I really almost expected to have a HPFP failure and that would be a little easier to take at 60K because Ford can't control what's in the fuel. To say I'm disappointed with the quality of my truck is an understatement. Like so many others on here that have had problems I have been a Ford guy ever since I started driving over 40 years ago. Everybody that knows me knows that I love this truck despite the other problems I have had. I'm not swearing off Fords because of this, I guess I have my eyes a little more open now. Ford can build just as big a piece of crap as any of the other manufacturers. So I will take my lumps and fix this truck. I will probably sell it before the warranty runs out on the new engine. I will not own another Ford diesel which is really too bad because I really love everything else about it. I just don't trust it anymore. I do like the newer superdutys and the 6.2 seems to be a more reliable engine so I might end up with one of those. I don't really have to have a diesel, I wanted one but not bad enough to buy an engine every 60K.