Moose, good post and one I had wondered about.
I was viewing an article on best engines a few weeks ago, I just looked to see if I could find it again, but couldn't. Anyway this article had the Ford 4.6 Modular engine as one of the top 10. Reasoning if I remember correctly was the many. many taxis and cars this engine was in with high mileage, many 400k+. So at the time I ask myself, wow how can that be? The 4.6, 5.4 and the v10 are all on the same platform. Is it a maintenance thing???? I don't know, I certainly believe in maintenance after a career of maintaining equipment and buildings for 30+ years. I do believe these engines "can" be very good engines but much more complex then engines of the past, like the 350 chevy. The Chev makes everyone's best engines ever built and arguably the best engine ever manufactured, but compared to the Modular a very, very simple almost child like engine. Is Ford to blame for these engines and their related problems? Wow, again we have those who have put 250k+ miles on them with no trouble and then we have Dave, who originally posted this thread with 99k and dead so I really don't know. I think if I was Ford I would look at every individual case of engine failure and do what I could do to help resolve the issue with the vehicle owner. A quick check of the oil pan and under the valve covers would indicate an engine that had been properly maintained, or at least a fairly visual on if it had been happening. If like the other post we have on the Forum that it had been 16k since the last oil change I would tell the owner, too bad, so sad, have a great day.
Its sad these engine/transmission conditions happens on these late model vehicles, its certainly a financial loss to the families. AND it pushes good hard working folks away from Ford and American made products to Asain or Korean made rigs. All the 10 best engine/vehicle articles you can find are stacked with Toyota's and Honda's and their high ended associates.
Dave is facing some tough choices, putting lots of money into the rig or selling it for junk prices.
Or putting some heavy oil in it to see if it quiets down and sale it.
Gary