Noelvm,
I was supposed to have an intercooler installed but now it`s an engine that will be replaced. The dealership has the intercooler and parts. Call 334-626-7777
ext. 311. Ask for John or JT
If you can't get him...John and JT are the same guy. Ask for David in the Parts department.I just got off the phone with John about 5. They will do the deal for you man.

 

Thanks, I started the ball rolling. I will go to the dealership tomorrow to make sure they don't drop it. many thanks,
noelvm

 

Twisted99,

What made the dealership decide to swap out the engine?

 

It was the sludge that was in the intake,intercooler and blower. The twin screws had the stuff all over it and the intercooler was plugging up bad. I thought I observed the boost increasing...and or spiking compared back before the leak started. It really may help to have a good relationship with your Dealer\Service department but I really don`t see why they would have a problem replacing any engine when the intercooler leaked. If you look at Ford's own cost of repair\operations estimates for the Lightning they are very high. My understanding is that invoice is around $26000. for these trucks. Supposedly Ford nets $11000. These figures are rough.
If you saw your intercooler had what appeared to be sludge,thick enough to wipe off with say your index finger and not have it drip off over a time period...Thick gunk....you would be adamant about replacing the engine under warranty. Ford is aware they have intercooler leaks and they need to ensure that Myself and everyone with this problem is taken care of..Complete satisfaction. I hate to imagine what amount of this gunk got under the valves and the extensive damage that it most assuredly imparted. From the crankcase the vapors must be heavy enough to cause a chemical reaction with the coolant..and any who use waterwetter may make it worse. The leak is Fords problem...anything after that as well.
This stuff was like mollasses in winter....or say heavy 140 weight. Imagine the backpressure\increased Differential across the intercooler. I`m not certain but need to find out where the tap for the Boost gauge is. Is it under the intercooler or under the screws in the blower? Think about the axial\radial dynamics on these pieces.

Who knows how long the rings would last even if this goop is in the cylinders as well...which would be pumped through this engine ....

 

Hey, got the intercooler coming to my dealership today. I'm going to print out the above post and tell them to call me so I can personally inspect the engine when it is apart.
Thanks again TWISTED 99
NOELVM