Forensics of my 2003 Ford Motorcraft Remanufactured 6.0L

[@CheapRidesAutoSales]

I am obsessed with this channel, this guy is a world of knowledge after years of working and studying this engines, i feel like i know nothing compare to this guy.

[@toomanytoys]

Thanks. Nah, I'm still learning.

[@ktate2002]

My disappointment is beyond measure. I’m sorry for you but I’m very grateful you shared your documentation with us.

[@toomanytoys]

Having worked with Ford on supplier projects for 30 years and being a Ford Fan since 9 years old, I was a deer in headlights. This was an onion, where I realized I had to go deeper every time I disassembled one thing. I never expected that, and it certainly has changed my attitude. Normally, I don't broadcast things like this, but once I found out others had similar experiences, I had to publish this. This is just plain wrong and a hard lesson, even at my age.

[@davidchristensen6908]

For $16,424.68 even after 75k miles on this motor Ford remanufacturing owes you something. With your credentials and your documentation the bean counter need to be beaten. Wonderful video because I couldn’t rebuild an engine if my life depended on it but you made it so even I can understand.

[@toomanytoys]

Unfortunately, I was told it would be a tough road to deal with due to the length of time since buying it, and I would have to retain paid experts to present the case.

[@georgesrisomsak9650]

The amount I have learned in the last hour on an early Sunday morning is astonishing. Reading through the comments, and leaving a handful of likes, I learned some there too even. I've been a subscriber for some time, however missed this video. I wanted to thank you for the invaluable information you've taken great lengths to compile and share. Your videos are always concise, to the point, incredibly detailed and offer a wealth of information. It's apparent you've been in the auto industry for quite some time, and the experience shows in the videos immensely. I must say, of ANY video on any platform of a 6.0 powerstoke teardown, this is the absolute gold mine, the plethora of info that every 6.0 enthusiast should know. Thank you greatly for the time taken to produce and post one of the most thorough videos I think I've ever seen on one of these. As a previous Ford diesel technician, I commend you for your outrageous ability. Amazing work my friend. Just simply amazing.

[@toomanytoys]

Overwhelmed, sir. Thank you very much.

[@donalddavis581]

after I retired from a 40+ year position and doing machine work..long story.. I took a job with a company maintaining their 30 transit buses. Most of them had 6.0L and we had our fair share of issues. I also drove an 2004 6.0L myself and had issues with the normal 6.0 things... The bus company delt with a local Ford dealership. Lots of young guys. Overall the quality or lack there of was astounding... Obvious lack of any personal craftsmanship, most times... Lost a radiator bringing one back where the radiator was installed using zip ties. Yup ASE certified Ford 6.0L service tech.... sold my personal truck while it was still running good... and retired a second time. I personally have little tolerance for shoddy work. I did enjoy the video... I had spent a lot of time with those engines....

[@toomanytoys]

Thanks for adding your story.

[@RobertWilliams-mk8pl]

Outstanding assessment. Your machining background gave you an extremely discerning eye. Beautiful. Unfortunately, there are individuals like yourself that have more knowledge than entire engineering departments. Largely engineering degrees only reflect that many or most that have them were simply disciplined enough to have remained in class.

[@toomanytoys]

It was just bloody poor workmanship, not what you should have from an OE company.

[@22howards]

This is right in line with the electrical videos. On target. Another builder on KZbin showed the same. Ford is looking to protect its bottom line in getting the most value for a replacement line of parts. Whoever this builder was/is they certainly fell short in the objective of a quality reman part. Thanks for your consistent methodical disassembly of this engine. Please keep the videos coming!

[@repentfulsinner]

I have been studying this motor for 3 years and cannot believe how many things I can still learn. Thank you for helping the community.

[@zk5416]

It's a Ford. Nothing more needs to be said. Great video. Thanks. A rod bearing went out on my 6.0 l Powerstroke on Friday after new headgeskets, two new injectors, new water pump, and new engine wiring harness were done. I bought a used Toyota on Saturday and put my F-250 up for sale on craigslist.

[@toomanytoys]

These can get up. Was that a stock lower end or reman? All the other Ford's in our lives had been good.

[@wulfmans]

This shure should have got you a new motor. This is one of the best tear down vids i have ever seen.

[@toomanytoys]

Thank you. I don't think they would release the money unless they were forced to.

[@wulfmans]

@@toomanytoys Well I am an electronics engineer with a auto shop at home. I do everything myself. Now that i saw the reman engine and the mistakes and poor quality, I would never buy anything reman from ford. Even though Ford is my favorite brand of car/truck.

[@CTCB4Z]

Just saw this for the very first time and what a surprise at the very end. Please come post up more on the Army.

[@toomanytoys]

I do post there; I usually check every few days. I don't often post my videos on sites as I don't want to push them.

[@CTCB4Z]

@@toomanytoys you should definitely keep us updated on your build. Been doing the 6.0 dance for 12 years now and have learned alot just from your research. Simply amazing. Thank you

[@tdotw77]

That was an Amazing video. So much information in here. Thank you for taking the time to document all of this so we all can see the remanufacturing process Co. hopefully Ford no longer uses. 🤷‍♂️🤔

[@toomanytoys]

Thanks for your comment. That really was a painful video to do. I've been Ford Blue all my life, enjoyed working with the Ford people during my career more than the other manufacturers. It was as though this engine was supposed to go to a tech class where they would pull it down to find problems. I never would have imagined so many issues in one engine. And from a major company. My understanding is Franklin Power Products is no longer in business, and another company is doing the rebuilds today. But still, for Ford to let this type of work go out into the field and not catch it with due diligence is problematic.

[@tdotw77]

@@toomanytoys I am a die hard Ford fan also. My dad worked @ the stamping plant here just outside of Buffalo(in Blasdell), so I think I got a lil partial from that. 😆 I became addicted to the Diesel tho once I saw their power - pulling a bobcat loaded trailer w\out even noticing it was there, and going to tractor pulls, I was instantly hooked on the power. Now after owning 3 different 7.3's('00, e'99, '00 f250's) id never go back to a gas motor - in a truck, at least. It's such a good, simple motor. I do love the 6.0's tho, but I'm scared of the potential problems, w\out a $$ security blanket waiting. Maybe someday.... Anyways, I know everything has its problems but yeah you definitely got a 'built on Friday afternoon before a long holiday weekend' engine!! 😄😢There's no way all that should've passed any QC at any place, especially a 'Ford factory reman'!! I think Ford was so behind with all the 6.0L problems\warranties, they were throwing them together to get them out the door asap, & so there went the quality control aspect👎. At least you are qualified enough to do what you had to do to get it going again. Thanks again for all you've done. I wish I was your neighbor, so I could hear some of the many stories you had to do earlier in your career, I'm sure you could write a few books on it!📚👍📖🤔🛠️✔️

[@kotech2003]

This is just plain appalling and why I will never recommend a Ford reman engine to anyone.....I was fortunate to find an engine rebuilder in the city of Houston that knows the 6.0 well and rebuilds them all day everyday without issues like the ones you've shared. Thank you for the detailed video. Keep up the good work

[@haleyy68]

R.A. Deyang. Who did you use in Houston? I have a 6.0 and need a good engine tech. Thanks

[@kotech2003]

South Houston Engine

[@matty86suk]

Very fascinating, thx for taking the time to make this video.

[@Rift45]

Amazing how bad it is, especially considering the price. Thank you for the wonderful analysis!!

[@toomanytoys]

Thank you. It's not what I expected at all. The deeper I went, the more I found.

[@bradalexander1]

love how detailed you get into everything! Thank you! Cool to see my trucks motor from a new point of view!

[@taylorsutherland9447]

Excellent teardown and diagnosis, as unfortunate as it was. It really shows that if something must be done correctly, it must be done in house. Farming out things like this leaves too many unknowns. That rod bearing is just unacceptable, and the debris is proof of sloppiness at its best.

[@toomanytoys]

Agree, I could not believe what I was seeing.

[@ChrisR]

Having watched fords "remanufacturing process" video, and seeing what you got, it's obvious you did not get what you paid for, and the engine was not assembled correctly. I'm reminded of the phrase "If you want a job done right, you have to do it yourself....."

[@toomanytoys]

Kind of a bait and switch. I wish I kept the pamphlet that I was handed at the dealership. Better than new.

[@johndkoop]

excellent video thanks very much I appreciate the detailed analysis. I come from an aviation background and I can see the rebuilder has production and cost at the fore front as priority, versus quality and there are several human factors issues that caused some of these problems. Either Ford doesn't know or does not care . Shame on them.

[@casualobserver620]

Ford Motor Company: We use only original Ford parts with the highest quality machining only Ford can achieve with quality checks at every procedure. TooManyToys: Ahheemmmm....lemme show you something.

[@toomanytoys]

Yeah, funny thing about that.....

[@kwippl4207]

Awesome video! Excellent job with measurements and recording them. I honestly hope that you have sent your video and your measurements to FORD. They need to refine their QA/QC on remanufacturing. I have heard of the horror stories about these engines, but I bought a 6.0 anyway as I thought it would be a great project to both learn and have fun with (I am a Mechanical Engineer). I am in the process of tearing an original 250k down (not remanufactured). The engine was reported to have compression issues but inspection of the heads and block indicate a good seal. The cylinders have worn to the point where they are glossy, the oil was thick (poor maintenance), and I am just getting started on the heads. I want to thank you for your videos and explanations. Keep up the great job and have fun with them!

[@toomanytoys]

Thank you for your comments.

[@winstonsmith3685]

Very interesting video. Thanks for taking the time to make it.

[@toomanytoys]

Your welcome. No one should be in this situation unless they are buying a low-ball engine.

[@drbichat5229]

Years ago a mechanic friend of mine was working on my 1951 Morris engine and showed 2 engines he was working on, one was a FIAT and the other a FIAT clone made by Lada. The surfaces in Italian engine were smooth and perfectly machined, while the Lada was rough, with many grooves and striations like the ones you showed. Sad to see that in an American engine

[@toomanytoys]

There's still hope, it was a rebuilt American engine.

[@hotrod6919]

I parked my 03' a few months ago to catch up on my other projects but brought her home due to hanger inspection and she wasn't happy. No knocks, just leaking n smokin a ton and didnt wanna start. Think its time I dig into and pull apart my high mile spare 6.0 my brother donated to me. 300k but was well cared for vs mine with a hard 160k unknown histroy but by looking at how my interior first looked like it won the Baja 500 twice with the windows down.Its a typical rice farmers old ranch truck, Think I have almost everything for a budget refresh. Hopefully the rings and Bearings are pristine. lol

[@toomanytoys]

Good luck with it, Steven. Just take your time.

[@davec7]

Wow man great video !!! I've been surfing youtube for ford reman engine videos. It's starting to look like they practice the same money saving principles as other rebuilders. Another reason why I believe any engine rebuilt by someone other than yourself should anyways be disassembled or atleast inspected right away. 👍

[@toomanytoys]

Thanks 👍. I don't disagree with that. This was the first rebuilt motor I've ever bought, although as a hobby and necessity building motors myself for over 50 years for the farm, personal, and restrorations. I'm just hoping others don't make the same mistake.

[@maraudersr1043]

Excellent postmortem... I saw the remanufacture video and noticed those folks are hustling to get things done. Like all companies these days the business motto is to "do more with less". Isn't that the real issue?

[@toomanytoys]

From a person who used to work there, management allowed people to get away with a lot.

[@buyamerican3191]

Outstanding video! So much great information here and presented so well. Your videography is outstanding. I look forward to hearing more about this motor. Are you planning on re-assembling and re-using this engine? Is it possible to make it dependable and at what cost? It's refreshing to see a presentation by a professional unlike the usual "know-it-alls" in this venue.

[@toomanytoys]

As I go through the motor, I'm making videos of what I'm doing. I'm desperately trying not to spend money on it but using every method I've learned to reliably turn it around. And using the video's so people might be able to utilize some of what I'm showing to rework their own. Not that I'm endorsing DIY like I am. The life of this truck is dependent on the Northeast rust, not the build quality of the motor, so I can play some .... this time.

[@norman_sage2528]

I have seen extra parts left behind more than once, so it did not phase me a bit. But if I had removed the number 4 rod cap, 24.00, and saw that crushed tab, I would have yelled at least five obscenities that my neighbor would have heard. Goes to show that Corporate Ford has a lack of respect for the consumer. Anyway, thanks for the video.

[@toomanytoys]

I named the motor Pandora. Every time I went deeper, I found a new issue that blew me away. I know a very good mechanic and builder who said this was like a high school auto shop build. I went more detailed with certain things just because I was in disbelief this could have happened. It wasn't like I normally blueprint every motor I've touched, but you get to the point of questioning everything.

[@erichkestler1934]

Great video. Thank you for sharing.

[@toomanytoys]

your welcome.

[@somewhereinoklahoma5574]

This was very informative and interesting.

[@toomanytoys]

Thanks.

[@scroungasworkshop4663]

Hmmmm, I just watched the Ford remanufactured engine video and it seems that Ford’s claims are complete bullshit. New genuine bearings my arse but how can OEM bearings cost Ford more than after market ones? Very thorough and informative video and I learnt a lot from it and I suppose I shouldn’t be surprised or disappointed by Ford as they have enough issues with new engines let alone remanufactured ones. They have too many people that don’t give a shit putting engines together with very poor QC. Imagine standing there all day sandblasting engine blocks? I have a sand blaster and after an hour I’ve had enough. I remember back in the late 70’s when engines were still mainly assembled by hand in the factory and some one would buy a car and it just went harder and made more power straight out of the box. They were one of the lucky ones when all the stars aligned and they got a Monday morning engine which happened to have perfect tolerances and was perfectly balanced. Some guys though got a Friday afternoon engine that would just give endless problems. Cheers Stuart 🇦🇺

[@norman_sage2528]

This is a Navistar engine. Ford did not manufacture bearings for it.

[@garrylum6025]

Bring the Barra back

[@1stockcam]

Lots of good info here. Thanks for sharing

[@toomanytoys]

Thanks for watching!

[@bad05ford]

This engine isn't a unicorn either. My local shop installed several and none made it a year, another guy got one made 90k and it dropped a couple lifters, ate the crank and a rod bearing journal up.

[@jimc9581]

Excellent job on the video, thanks for sharing your knowledge.

[@toomanytoys]

Thanks.

[@Nicky_Pin_It]

Love your videos. Keep em coming

[@Whatchamawhozit]

I like the front plate "Compensating" LMBO

[@Dwrecksk8Yo]

Wow if as much thought and time and planning and measuring went into your reman as went into this video then you might have actually got a good motor. Unfortunately the quality of work that they decided to perform was no where near the quality that you decided to perform. Great job sir. Keep it up.

[@toomanytoys]

Thanks. Really all I'm doing is taking care of all the little steps.

[@spankeyfish]

The first set of machining marks look like the insert on the skimming tool was toast. Carbide inserts tend to eventually get chipped on the edges and that can leave weird stripes in the part.

[@toomanytoys]

They just didn't care.

[@4X4F250Diesel]

Sadly this is all to true, I just rebuil a ford rebuilt 6.0 # 3 main looked like a rock was put between it and the crank. It killed lpop front cover bearings crank & cam. The crank was already turned down and was at the lowest spec, i don't see why they do that. I respect your knowledge I only wish to learn as much.

[@toomanytoys]

Man. sorry to hear that. A number of people have confirmed they found issues with these rebuilt motors too.

[@KyJack13]

Awesome job. Thank you

[@toomanytoys]

Thank you too!

[@stevestonacek7128]

I can not believe that one rebuild could have this many problems. The head and deck machining is subpar the misaligned rod bearing just blows me away. You would think that for that amount of money you get a quality product. If I need to rebuild my 2004 6.0 I will do it my self using good machine shop and not use a Ford rebuild. I think you might have better chance using and low mileage used engine from a wrecking yard. Thank you so much for this video.

[@seijirou302]

He'd have had better chances with a high mileage junkyard engine, let alone low miles!

[@jrhjk]

Great video as always

[@toomanytoys]

Appreciate that!

[@curtisanderson9984]

Thanks for all the great videos lately. Great information.

[@toomanytoys]

Thank you for the comment.

[@tdrewman]

I guess it is better to spend more taking your engine to a local machine shop to be machined. The video I watch showed so many fancy machines they use.

[@toomanytoys]

If I had the time to do it when I had to replace the engine it would have been a better choice. But you have to know what to look for at a local rebuilder. Another option I would recommend at this time frame is Ashville or KDD. CNCFab may be a good choice too.

[@gregoryclemen1870]

it is amazing" that engine " did not throw a rod with the bearing shell lock tab not seated(crushed/shifted), I am amazed that there was no" rod knock "either!!!!.

[@toomanytoys]

There was a noise; I heard it after about 20k, which I showed I was looking for at the video's start. It didn't sound like a normal con-rod or piston slap. It most likely was slightly mooted due to the twist of the shell. I was surprised to didn't get thrown either. But I've been told stories of these only lasting 100k, so it may have been close.

[@gregoryclemen1870]

you made a comment that the crank raised up when you removed the rod cap, I find it hard to believe that when that engine was going together, the crank was not turned over by "HAND" to be sure that none of the bearings are in a bind. I am sure that crank was "STUCK". so much for "QUALIY IS JOB ONE"!!!!.

[@gregoryclemen1870]

I did watch the "FORD REMANUFACTURED ENGINES" video, and I did noticed there are too many "FINGERS IN THE POT" I was raised on the idea that when you rebuild an engine that "YOU" do the teardown. every engine tells a story(just like your engine told a bad one). "YOU" do the clean up, and reassembly/ start up!!!!

[@cristinaalonsocao2486]

Excelent video,thanks for share

[@toomanytoys]

Thank you!

[@CrazyPetez]

Wow! Just wow.

[@toomanytoys]

Yeah, not something I ever would have expected.

[@drcolster]

Jack,send video to every Ford Boss, and Current Affair Shows..They should give you a new truck,, There work is Disgusting !!!.. Your Skills and Qualifycations are Outstanding,on them alone you should get anew truck.. keep well..

[@toomanytoys]

Thanks. Revenge is best served cold is how this series started, now I'm using the situation to use as a learning experience - for me as well as others.

[@Dwrecksk8Yo]

Yeah the funny thing is I saw the ford reman process video and was thinking to myself wow those dudes don’t care at all the way they were handling everything and then your video was on the recommended right after I watched that ford remanufacturing process video. I tore down my ford 2.0 zetec from a m8 bolt snapping off on the timing belt idler pulley and felt the surfacing from the factory left a lot to be desired and I corrected it from the very same lapping process that you did except I had never even heard that it was a real thing I just did it off of instinct and it worked. Then I saw the tsb from ford saying that causes of certain timing issues or head gasket issues could be caused from a mis machined head or block. Looks like it’s not that rare.

[@toomanytoys]

A "rest of the story" situation. LOL.

[@markhull1366]

Hello Sir. This is my second post to you. I have become quite a fan of your channel. I'm a retired Part 121 (Commercial) aircraft mechanic and really appreciate your methodology as it's a lot like how we operated in the airlines. I noticed you removed your engine from the front. I'm assuming this was the only method you had available. Generally, most places raise the entire cab off the chasis. If you had the option, which way would you choose? Did you find going through the front much more difficult? I was thinking of installing a 2 post lift in the shop, but am having a hard time qualifying that expense for the limited use it would get. Thanks!

[@toomanytoys]

Thanks Mark, I appreciate that. Retired too, I no longer have access to lifts either. In this case the initial work was going to be the rear lifters, so if I had done a cab off the trans would have had also to be removed. It wasn't that hard to remove the engine though the front.

[@davidmcnerney3048]

Once upon a time Ford was probly turning and burning Reman 6.0's by truck load. That rod bearing look like a pure case of not giving a hoot.

[@toomanytoys]

I found a comment from a person who used to work there that said no one gave a damn, including management. They just pumped them out. Some guys came to work high or drunk. I can't believe Ford did not do due diligence.

[@sanleon1314]

Most excellent video! Shame on Ford.

[@toomanytoys]

If it hadn't happened to me, I would have had a hard time believing it.

[@derektroost6980]

I am amazed that the bearing tab issue didn't cause a spun bearing.

[@toomanytoys]

Agreed. My eyes went wide, and a big hole opened under me when I saw that shell. I could not believe it lasted, and I could not believe anyone would be that careless.

[@derektroost6980]

@@toomanytoys I've caught that error on builds where I work as part of the job I do is to double check work done by others. As I'm sure you are aware Its very easy to notice even when everything is assembled before the pan is installed as there will be no end play sliding of the rod on the crank. Hard to stomach. Glad to see you still seem to have a sense of humor about the whole thing and your sarcasm is appreciated. I'm convinced of the importance of teaching my kids how marketing propaganda works, your videos here are very helpful in that regard.

[@toomanytoys]

@@derektroost6980 Yep, that works. I still contend it should have been caught with a quick visual once the crank was laid in place. I can't remember a time when I didn't do that visual check.

[@ayoutubechannel921]

Are the newer ford remans any better?

[@toomanytoys]

I hope they are, but I can't say one way or the other. The company that did mine, Franklin Power Products, is no longer in business. It would be great to say all is well, but Ford dropped the ball doing due diligence with my engine, and I'm not sure they are doing better since right now, Ford has more recalls for new vehicles compared to all the other OE manufacturers. It doesn't inspire confidence in the company culture.

[@Robert-S-]

Sadly this does not surprise me at all. Like you said, any one of these mistakes is statistically possible....but for all of them to happen? Just carelessness. Take a look at this Ford Reman head being surfaced to get it flush, straight out of the box. 2014 - kzbin.info/www/bejne/e5vEqoBqgMtreK8 2017 - kzbin.info/www/bejne/jpTSn4l6btyGq9U Both appear to be similar problems to what you were showing at least on the head / block sealing surfaces. As a fellow 6.0 Excursion owner, I look forward to your follow up videos, your content has been very helpful so far. Thanks!

[@remb9614]

This terrible quality control is plaguing the industry. the reman John Deere parts and engines are almost expected to fail. No one is held responsible because you can’t narrow it down to one person. The vast majority of these engines and parts just get replaced and sent right back through the reman process. No one is tearing them down to see what failed like this gentleman. Lots of people opt to buy brand new stuff but the problem is most warranty work is done with the reman stuff.

[@quagmiredavis4117]

Should have gone with 5.9 Cummings conversion I did this four years ago and truck still running 6.0 is nothing but a boat anchor

[@toomanytoys]

When the original motor was damaged I thought about doing that. Taking care of my mother with dementia made it impossible at the time. Now the chassis does not warrant it.

[@rickh633]

I can hear a rod knock and bad guides. The starting issue is likely leaky standpipes. When stroking crankshafts everything is 1/2'd A .010 under stroker grind is +/- .004 stroke = .002 DH. .008 stroke in 010 under is an OEM fkup. I've been grinding cranks for far too long. After I setup on the worst journal, I roll the shaft to the next index location. I don't alter the stroke it's too much time. I do bump the index. Your problem is rod lengths or piston CH or the decks are not square. Your crank was probably ground on a Prince.

[@toomanytoys]

"I can hear a rod knock and bad guides. The starting issue is likely leaky standpipes. When stroking crankshafts everything is 1/2'd A .010 under stroker grind is +/- .004 stroke = .002 DH. .008 stroke in 010 under is an OEM fkup. I've been grinding cranks for far too long. After I setup on the worst journal, I roll the shaft to the next index location. I don't alter the stroke it's too much time. I do bump the index. Your problem is rod lengths or piston CH or the decks are not square. Your crank was probably ground on a Prince." I've heard a number of rod knocks in my lifetime, this wasn't the same sound. The valve guides measured within the normal, useful range, not worn. When I changed out the crankshaft for an OE grind, the piston protrusion numbers came in normal, so it wasn't the connecting rods or the block, it was the crankshaft.

[@grumpyg9350]

Wow.......Their ISO certification needs an audit.

[@toomanytoys]

The company that did the rework for Ford is not longer in business. I can't imagine why.

[@Whatchamawhozit]

@@toomanytoys Well thank god they are out of business, could you imagine how many of these bad motors are on the market. Btw have you tweeted or tagged #Ford ?

[@elbuggo]

Good vid!

[@toomanytoys]

Thanks!

[@maxpower9848]

You spent money on a early build?

[@toomanytoys]

The early builds have a more robust ERG cooler and HPO plumbing that rarely leaks compared to the standpipes and dummy plugs of later years. The '03 cam has a more aggressive lobe separation, half between the later stock cam and a Stage 2 cam. Between it's programming and the cam, the early motors have been known to develop more punch at the lower end. My truck also still has the original programming with the pilot injection, so once you get above 150º idle is very quiet. According to Charlie at KC Turbos, "So over the years the turbos lost top end power, increased spool up, and got quieter." The main hangup with the '03 is when you have a failure of the HPOP, the reliability of rebuilt units is not great, so you have to spend an extra $100 to get a HPOP from CNCFab or more expensive from DieselSite. The '05 HPOP have a better reliability stock, but they do fail, just not as a high or rate.

[@johnchristensen3030]

bean counters. Charge top quality prices and hire unskilled, untrained labor. The bigger the sign and the fancier the new building the lower the quality of products and services.

[@toomanytoys]

It was something I didn't expect out of Ford.

[@AquaGreenORAganicsWestLinn]

Omg they really assembled your engine with the deck in that condition, that one should be covered under warrenty no questions asked. 5k or 500k miles on a cert Ford re-man ajd the 2-5k they cost there is no way that it should have pasted QC ever. I'm so sorry you had to go through that Ford should make you whole.

[@toomanytoys]

I wish. The entire motor looks like high school kids put it together.

[@AquaGreenORAganicsWestLinn]

Wow, unbelivable... what is this country coming to what happen to a sense of pride in doing a job well done?

[@toomanytoys]

​@@AquaGreenORAganicsWestLinn It's a double whammy. Not only was the commissioned rebuilder at fault, but Ford's Motorcraft group also did not do the diligence of auditing the supplier. I'm not sure who to blame more, but for what Ford charges for this replacement, I'm more inclined to put the blame there.

[@justinvegan]

Do you recall how long you used ELC coolant? Was it one with Nitrate?

[@toomanytoys]

This motor always had the Rotella ELC, not the nitrate free. It was given to the dealer when they put the motor in.

[@justinvegan]

@@toomanytoys Awesome! I just got interested in the Oil Cooler being chopped open & showing no signs of clogging. As for the differences in CT & EOT, perhaps, trying a new fan clutch might help.

[@justinvegan]

@@toomanytoys Back to re-watching your 6.0 video's again & Learning something new each time. Did you run a coolant filter during the 75K? You kept hearing the "Skip" in the engine & that's what prompted the tear down? I totally agree with your assessment that their is no justification for this type of quality... I'm outraged! Looks like It was a crappy engine to begin with & it was just put back together haphazardly. Thanks for presenting us with the facts & I guarantee you've saved others from purchasing one of these nightmares.

[@toomanytoys]

@@justinvegan Yes, the coolant filter was always on the truck, including the prior engine. The main issue I kept hearing was a sound like a piston slap at hot temps and speed. After tearing it down, I believe that was excessive connecting rod clearance from the incorrectly positioned bearing shell. Hot, thin oil made the sound worse. That is what got me to park it, which was probably a good move. Guys who do fleet work on PowerStroke Army say the Ford remans usually don't live past 100k. The second issue with the lifter made me think that was the real issue, and that is why I said to my wife (who keeps reminding me of this) I need a long weekend and under $100 of parts to fix it. The more I kept digging, the more I found. Initially, I wasn't planning on the "forensics" video, but this was just so poorly rebuilt, as you said, I didn't want others to make the same mistake.

[@justinvegan]

@@toomanytoys Thanks for your response! My consensus is the Nitrate in Coolant is what doesn't stand up to the heat in the cooler. I've thrown in the NF ELC in my 07' 6.0L so we shall see in the future what happens. The coolant filter, you installed, IMO helped you regardless & It's one of the easiest maintenance anyone can do to their 6.0L for longevity. Your already well aware of this but the dislocated bearing is definitely what caused the "knock" noise you heard. I've got another question for you & it's none of my business but curiosity getting the best of me... What happened to the original 6.0L that prompted you to buy the reman & at what mileage did you get out of it? From what I see you may of gotten 125K out of the original?

[@olavwendelbo5199]

The useless Ford reman workshop messed with the wrong man!

[@norman_sage2528]

Savage

[@dano4572]

how about,,,, next time install an electric pre-lube pump, with one 50psi and one 60psi pressure switches. won't start till both pressures are met.

[@toomanytoys]

That could be done and I've thought of it. But it's not worth it as this truck is a Northeast truck.

[@robj2704]

This is like buying a cheap battery versus an expensive battery. There's no difference except in the price. The price is the insurance policy the company builds into the product to cover the product's failure and the cost to replace it when it does fail. This engine is an example of short cuts everywhere. Ford took a chance that this vehicle would be scrapped before the engine failed, thus making the extra profit to more than cover risk associated with poor workmanship. A fresh, unsupervised trainee could have done a better job of rebuilding this engine. I just got through watching a couple Ford videos praising themselves on how well they rebuild their engines. If this engine is an example, that's a lie. It's all about slick salesmanship, pushing a product that doesn't meet reasonable standards. I was working in a car dealership when I was 17 years old, and rebuilding engines at that time having been trained by my father in his garage. There were practices in place those 55+ years ago that this engine rebuild didn't get.

[@toomanytoys]

Yeah, I agree. I think their concept is someone will put the engine in, and then sell or trade on a new truck after the experience. I heard from a number of fleet mechanics where their company goes this route and 100k miles would be lucky out of it. The one video for Ford Diesel engines shows guys with CAT on their shirts, but CAT had just bought the rebuilder. When you review the video you can see (now for me) the workmanship is not what you expect at this price. There is a forum post somewhere from a guy who use to work there, he said he could not believe the work that was allowed to be done.

[@Ascotman]

@@toomanytoys AER is another Ford Engine Remanufacturer, you can see "AER" on the rebuilders shirts in the Ford video for Ford remanufactured engines.

[@toomanytoys]

@@Ascotman AER is another company out of Texas that supplies Ford with the gas engines and also supplies other vehicle manufacturers with rebuilt engines and engine parts. The company that rebuilt this engine and other International based engines was different. The company initially was part of International's "ReNew" reman program but was purchased away from International and named Franklin Power Products in Franklin, IN, and continued to supply both Int and Ford with rebuilds. It was bought by Remy, and then in 2007 bought by Caterpillar, and definitely under Caterpillar when my example was made. I hope Ford is no longer using this company for the 6.7L, but then Ford's Motorcraft division is responsible for overseeing the product sold by the dealerships, then and now.

[@rwrenchrwrench4697]

OMG, you would have been better off rebuilding a junkyard core in your garage. $16500 for an engine that lasted 75K. i would have never expected that from ford reman. : (

[@toomanytoys]

I couldn't agree more. I was just at a bad place at the time where I could not do my normal hands on, and I PAID for that in every sense of the word.

[@erickmcmartin]

Are you sure this was a Ford reman did ford fit it because as an engine machinist engine builder that is very amateur

[@toomanytoys]

From a Ford dealer I knew, with Motorcraft reman stickers on it. The Motorcraft side of Ford is not the same as the OE side. They contracted the motors through International, who had sold its "ReNew" division to a private owner, who renamed it Franklin Power Products, which was bought by Remy and finally then Cat. The division is no longer in business.

[@markbeard518]

I hope i never do any work for you lol. great video though

[@toomanytoys]

LOL. When I do have people contract work for me, I've learned to step away and not be there.

[@norman_sage2528]

😂

[@SillyPutty3700]

Not OE per the video. Fraud has a 7 year unlimited mileage reach.

[@toomanytoys]

Unfortunately past that.

[@vintagedashboard6810]

Very unqualified machinists or steps were skipped

[@toomanytoys]

A man who worked there said the employees could get away with anything. Neither they nor the management cared. Ford's aftermarket side should have.

[@robflammia4716]

Two words....piss poor

[@toomanytoys]

I'd make it three with "Really" in front of those two.

[@tuf86sami]

I'd be irate.

[@toomanytoys]

More then irate, ticked off enough to make a video.

[@IronRiviera]

The builders should be ashamed.

[@toomanytoys]

Not shown in this video, even the reground cam was wrong. I never could have imagined ....

[@jo6520]

Send this video to Ford, demand a new engine!

[@toomanytoys]

I would not want a new engine from them.

[@norman_sage2528]

What would be the point of sending the video? The technical expertise of the corporate bean counters could only get them past the title. I'm sure they all have AAA to change their roadside flats. Not to get there hands dirty and all.

[@josephclemons4308]

Another ford job done shitty they are good at that that why i don't buy fords anymore

[@toomanytoys]

During my career, I worked with all the American manufacturers and some of the Asian and European. Ford is definitely not the worst, and this situation has to do with the Motorcraft reman products. That group is completely separate from the OE side of the business - I had to work with both.

[@josephclemons4308]

@@toomanytoys I've owned a few ford and i can say with confidence they are garbage

[@ktmfour1007]

Dont buy ford moral of the story.if Hyundai made a truck id pick that over ford

[@toomanytoys]

I would still buy a new Ford, and will. What I won't ever do is buy Motorcraft reman.