NHTSA Complaint #10243963 — 2003 FORD F-350 SD

WHILE DRIVING AT 70MPH A FUEL INJECTOR FAILED LITTERING THE #3 CYLINDER WITH DEBRIS. A BLUE SMOKE CLOUD IMMEDIATELY BLANKETED THE HIGHWAY REDUCING VISIBILITY TO NEAR ZERO. FORTUNATELY I WAS ABLE TO FIND A SAFE LOCATION TO PULL OFF BEFORE THE ENGINE SEIZED. I TOWED THE TRUCK TO THE FORD DEALER FOR AN ESTIMATE FOR REPAIRS. I WAS ADVISED THAT A FUEL INJECTOR HAD FAILED AND IT COULD BE REPAIRED FOR $750. I AUTHORIZED THE REPAIR AND RECEIVED A CALL THAT AFTERNOON THE TRUCK WAS DONE HOWEVER #3 CYLINDER COMPRESSION WAS HALF OF NORMAL. THEY RECOMMENDED A "SHORT BLOCK" WHICH COSTS $8,000 PLUS LABOR. I WAS ANGRY AND PAID THE BILL AND SOUGHT OUT A SECOND OPINION. I CHOSE TO REPLACE THE ENTIRE ENGINE AFTER SEEING THE DAMAGE AND ON THE ADVICE OF THE SECOND MECHANIC. I DID NOT WANT TO PUT THE OLD INJECTORS INTO A NEW MOTOR. THIS WAS NOT THE FIRST INJECTOR TO FAIL ON THIS TRUCK, HOWEVER THE FIRST DID NOT CAUSE CATASTROPHIC FAILURE AND WAS COVERED UNDER WARRANTY, I HAVE HEARD OTHER ANECDOTAL REPORTS OF SIMILAR FAILURES. THIS WAS A WELL MAINTAINED VEHICLE WITH ALL THE WORK DONE AT FORD DEALERSHIPS AT THE RECOMMENDED INTERVALS. I HAD THE MECHANIC SAVE THE DAMAGED PISTON WHICH BEARS THE IMPRINT OF THE INJECTOR DEBRIS INCLUDING PARTIAL PART NUMBER. BEFORE TAKING THE TRUCK FROM THE DEALERSHIP I HAD THEM SUBMIT A REQUEST FOR ASSISTANCE FROM FORD TOWARD THE REPAIR WHICH WAS DECLINED. I BELIEVE THIS PART FAILED PREMATURELY @ 120,000 MILES DUE TO A FLAW IN DESIGN OR CONSTRUCTION. I HAVE A REASONABLE EXPECTATION OF GREATER LONGEVITY FOR A HEAVILY BUILT DIESEL ENGINE FOR WHICH I PAID AN EXTRA $6000 OVER BASE PRICE. A FAILURE COULD EASILY HAVE CAUSED AN ACCIDENT DUE TO THE THICK BLUE SMOKE OR THE INABILITY TO GET THE VEHICLE OFF THE ROAD UNDER ITS OWN POWER . *TR