Sorry for the length, but want to provide as many details as possible
2011 Flex AWD ecoboost 61,000 miles.
10/29/2016
there was a loss of power. Took to local MA dealer and they said the front turbo was gone. They replaced it under warranty and all was fine, until Christmas. Another loss of power and back to the same dealer. This time both turbos are bad and there is metal in the oil filter. Same dealer said that they can't handle the job and tie up a bay for that long, and I should take it to another dealer. #2 dealership took the appointment after I provided a full run down on the issue and the previous repair. Had it towed to #2 dealership by AAA. They looked at it and said that they can't make another claim on it and it needs to go back to dealership #1(insinuated that dealer #1 improperly installed turbo). I asked dealership #2 to contact dealership #1 and explain the situation and make arrangements to get it back to dealership #1. When I spoke to dealership #1 they had not been called by dealership #2. I escalated the matter to Ford Customer Service and I'm expecting the worse.
1/14/17
Dealer Service Manager told me that he had talked with Ford engineers and they wanted documentation on oil changes and have his techs pull the valve cover and oil pan to check for sludge. I told him that I did the oil changes within the spec mileage and spec oil and filter. He called the next day saying that everything looked good no codes being thrown, and Ford is recommending replacing both turbos, running it, then changing the oil, and repeat. I asked him if his tech had scoped the cylinders for damage, checked the main &cam bearings, and done a leak down test. To which he replied "no". I reminded him that the initial inspection which found metal in the oil filter had recommended a complete tear down. He said that the Ford engineers said it should be fine. I told him that I am not comfortable knowing metal was found and no further inspection was recommended and I doubt that the engineers would be comfortable cutting corners like that on their own cars. The Service Manager also said that I need to bring the rental after 5 days but was working with Ford to extend that time because the turbo feed and return lines are on back order with no idea when they'll be available. I told him "with 700,000 ecoboost engines built and no lines to be had, it seems like the engines are eating the hoses and probably eating turbos as well"
I followed up with a call to Ford Customer Service and told them them my concerns with the original assessment and recommendations to tear the engine down. Also highlighted the potential for a serious decrease in service life if the metal damaged critical components.
2/5/2017
Update: got the car back on Thursday, after a month at the dealership. Two new turbos and a new intercooler(no new crate engine as I requested). Today is Sat. I had it on the highway and accelerated to cruising speed. Noticed the revs going up and speed staying the same or dropping. Tried to maintain speed and it just died!!! Tach went to ZERO!!!
No limp mode, no nothing! Risked life and limb to get across three lanes and off the roadway. Tried to start it and white smoke coming from the hood. Strong smell of electrical burning. Had three kids in the car so had them get out quickly and to the tree line behind the vehicle. Thought it was going to catch on fire. Checked under the hood and it wreaked of something electrical burning. Loosened the cap just a hair on the coolant tank and it started to fill quickly with scolding hot antifreeze. Tightened it quickly to avoid a scalding. Got back in and tried starting it, wouldn't even crank!! Had it towed back to the same dealership. Engine seized and right side axle shaft popped out of tranny. No spare engines anywhere, and a serious shortage of spare parts.
When it seized I was on a four lane highway with no breakdown lane. I had three young Children in the car. Had to make an emergency b-line for a very short window of opportunity to get off the road between guard rails. Tried to start it back up and white smoke pouring from under the hood.
