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Another quick update on my experience here. So it's been in the shop for 7 days. The master tech has recreated the problem multiple times for Ford, doing everything they ask (and Ford taking its sweet time responding to the tech, sometimes 24hrs or more). Ford got back to the service manager yesterday, saying they are declining the turbo replacement with some ridiculously long explanation that rattles are normal at varying RPM levels and that because the vehicle isn't logging any turbo specific codes, and that it's not hampering operation, that they aren't going to replace them. BS! The dealership is trying, so I can't fault them.
So the Service Manager told me to contact Ford directly and try it from my end. He gave me the details I needed to do so, and I got started. Called the 800 number, first agent I got tried to tell me that that's not how the process works and that I cannot create a case for the issue, that if ford is denying the warranty claim that's it, too bad. But she then hung up on me while trying to take me off mute, so I had to call back in. Got someone else, in a completely different country who I could hard understand, but this guy at least took all the information and said he'd be contacting the dealership, and trying to see what he could do. Funny how you get two very different responses within an hour. I have very little confidence that Ford is going to try and do the right thing here. And frankly it just really ****** me off that they think a rattle noise from an $80k vehicle is "normal". I don't give a rats ass if it doesn't hamper operation, when I pull up next to a 2020 Yukon, do I hear a sound that sounds like a loose heatshield coming from it. Hell, does the 2020 expedition I'm driving as a loaner do it, no... Not impressed, but I'm left feeling like a typical consumer these days, you're stuck. You either take a massive loss ($20k+ at this point) and get rid of the vehicle, or you suck it up and deal. Being a consumer in the US frankly sucks these days. Sorry, ranting now. I'll update if I hear anything back from Ford, but it's been in the shop now for a total of almost 20 days in the first year. I wish I could charge them for my time, and effectively 20/30ths of a loan payment at this point for loss of use and depreciation.
Honestly, I am not too concerned about the turbo rattles. It is a hinged system with no guides, in my mind it has to have some slack to seal correctly. If no slack is allowed it may seal crooked and leak.
I am more concerned about the cam phaser issues.