My 07 KR SuperCrew has developed a bad exhuast leak on the passenger side. It turns out the exhaust manifold is warped. The truck has just under 39,000 miles and I have used the truck for some light-medium duty towing, but nothing major and the truck is babied most of the time.

Is this a common thing? I searched and found some threads about it, but it seems a bit early for that to have happened. Has anyone else experienced this? I was just curious if this is an ongoing issue or just a one time thing.

I love the truck, and that is the only problem I have ever had. The dealer stated that since I bought the truck from them originally when new and returned it there for service Ford Motor will pay 80% of the repair costs, which takes the $800-900 repair bill they first quoted me to about $150-160. I can live with that.

Thanks for any help.

 

A buddy of mine had an '06 that he traded recently and within a week of the trade the dealer who took in the truck had to replace both manifolds to do warp/cracking. I was kind of surprised myself, just seems weird.

 

Late 06's and all 07's have a 5/50 powertrain warr. The exhaust repair should not cost you anything. If they try to say that the manifold is not covered under the powertrain, then tell them it's covered under emissions equipment which has a 10/100 on it.

 

my 04 did this. i actually hated driving it with the noise...got it fixed and a new truck again! something with the bolts i believe. not an expensive repair at all or long.
Jim

 

Thanks for the info. Powertrain is covered for 5yrs/60,000 miles and includes the exhaust and intake manifolds. Link to warranty: Click. Details on page 12.

I pay nada!

FYI: Emissions coverage is 3yrs/36,000. Details on page 18 of above link.

 

At least your getting it fixed and not paying for it. In your first post, it sounded like the dealer was trying to get you to pay and getting money from ford at the same time, in other words double dipping. After all the dealer should know that an 07 150 has a 5/60 powertrain warr on it and the exhaust manifold is covered. If I were you, I would take my business elsewhere from now on, and at the very least report them to ford.

 

It does sound shady on the face of it. The dealership, O'Brien Ford in Shelbyville, KY just changed hands a few months ago. It used to be Pearce Ford, a family owned dealership where I liked to do business and was well taken care of.

I was told by two different service writers that the exhaust manifold was absolutely not covered under either the Powertrain or Emissions warranties. I'm glad I did my homework.

I think I'll play "dumb like a fox" and see if they ask for payment when I go to pick it up in a few hours. If they do, I'll ask to speak with the manager and if need be, I'll show him the warranty info I printed out and see how his attitude changes.

I'll update the thread later on after I get home.

 

The service writer just called and informed me they ordered the wrong manifold gasket! I'm thinking this will be my last business transaction with them. They either didn't know the warranty coverage or tried to scam me and Ford, plus they can't order parts. Either way, I'm going somewhere else when I get my truck back.

The upside is they're giving me a loaner. But I had to raise Hell to get that. I'm not real happy with them right now.

 

All is well. They fixed the warped exhaust manifold under warranty, however they did ask me to pay nearly $150. I then informed the service writer that the repairs should fall under the Powertrain coverage, and she emphatically stated that my mileage (38,887) showed the vehicle was out of warranty. I had to enlighten her about the extended powertrain coverage for 07's and that the exhaust manifold was specifically listed as a covered part. She then asked me where I got this info, and she did some checking after I told her it was on Ford's website.

Instantly, her whole demeanor changed. She suddenly became very cooperative, considering that when she entered the part number and my mileage it immediately showed on her screen that it was a WARRANTY part. She then apologized and changed my service ticket, and gave me a coupon for a free car wash. Yippee.

I'll never go back to O'Brien Ford. I shouldn't have to educate them about what is covered. I'm also pretty certain they were going to bill Ford for the entire thing. Even if it was an honest mistake, I'm sure they would not have refunded my money voluntarily when they discovered their error.

The thing that bothers me most is that in this economy Ford cannot afford to have dealership personnel costing them business. As the son of a former Ford employee and a big fan of the Blue Oval, I have high hopes for Ford to emerge from this recession with a much stronger market position than its domestic competition. Dropping the ball, intentionally or otherwise, at the dealership service level only makes the task of those in Dearborn that much more difficult.

Thanks for the help everyone.

 

How do you know if the manifold is warped? Recently my exhaust note has changed and sounds like crap, I can really here it when I am next to a concrete barrier on the road. Anyone have any idea. I have an 05 FX4 with extended powertrain warranty.

 

It has to be pulled and checked on a surface plate to see if there is deformation. The leak will sound like a ticking or hissing noise that increases in speed relative to engine RPM. An easy test is to have a friend cover the exhaust pipe with their hand (preferably with a glove on, if the pipe is warm) and listen for where the sound gets louder. This will help you pinpoint the location. I originally thought it may be coming from the collector, by this test showed me it was the manifold. If it does not get louder, then the sound you hear is probably not an exhaust leak, although by your description it sounds likely.

FYI, a warped manifold is not the only cause of an exhaust leak. It could caused by a loose manifold bolt/s, exhaust manifold gasket failure, or a loose exhaust clamp on the collector pipe just aft of the manifold.