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Powdered metal parts are also widely used in jet engines, power generating turbines, etc. Powder delivers the most uniform grain structure achievable in the world of metallurgy. Powdered metal has extreme uniformity and drastically reduces reject rates in manufacturing. The alloys can be custom...

Porosity in the integral structure of a powdered metal part would be exceedingly rare. I've never seen it. The way these parts are made makes that unusual. Surface porosity is an intentional design element.

The porosity is intentional. It is part of the design of the part. It maintains lubrication during startup, etc. This material is quite common in these types of applications. "Billet gears" sounds cool but could easily have worse tolerances, poorer pumping performance and not contribute at all...

I've been involved in the business of machining things to close tolerances for 40 years. I'm not saying it's impossible to make billet gears to very close tolerances, just VERY difficult. There are machine tolerances, tool sharpness, operator competency, material variances, etc. PM is used...

The OPGs look like powdered metal. This technology is used when close tolerances are required. PM has been used extensively in connecting rods and other critical components for many years. I've seen the theory posted many times that Voodoo "RPM, load and vibration are causing the OPGs to fail"...

Wow, a dry sump system would have been amazing. Lower center of gravity with no oil pan and no issues with cavitation during hard cornering. The hard core race cars always get it, but cost and complexity usually cause it to get axed for street cars. Unless its a $150,000 Porsche or really...

Proof is a stubborn thing. The theory, presented in this thread numerous times, is that the Voodoo engine design creates vibration and stress on the oil pump gears that leads to their premature failure. Given that hypothesis, one MUST conclude that engines operated in the extremes of load and...

I've seen rod bearings fail from a piece of gasket or a lump of silicone as well. In reviewing the alleged OPG failure from the previous post, I think it likely that the Whipple blower's cylinder pressures were too much for the rod bearings at high RPM and the crank journal seized, spinning the...

Pure conjecture. A failed main bearing, rod bearing, etc would cause no oil pressure. Especially a spun bearing. Ford wants the whole engine back to analyze the failure.

Because the composite metal oil pump gear works just fine. There is not one shred of proof that even a single GT350 or Gr350R engine has failed because of it.

I DON"T KNOW, and neither do you. My guess is the human factor is to blame. There is good and bad in "hand built". I drive my GT350 like I stole it. I keep it under the redline and service it myself. If it breaks, I have a warranty. And I'm not one of those guys who seriously thinks this is...

If there is a direct connection between torque, load, vibration and the alleged OPG failure, wouldn't we see a preponderance of failures in engines that are raced? Lap after lap at WOT and near the rev limiter? But that's not what we see. We see a small number of truly random engine failures...

Yikes! I don't disagree with you. A billet pump would be better. $50 is nothing! But no one has proven that there is anything wrong with the existing pump. Components are built to do a job. they get SERIOUSLY tested and approved. You don't just make a component out of "unobtainium" because...

I don't know the cause. I'm not inclined to speculate. But I HIGHLY doubt that Ford green lighted a defective, or inadequate pump for this engine. Possible, sure. Probable? No way. I will quickly admit my error if I am proved wrong.

They have absolutely, positively no obligation to tell us anything. You can sue them, but you have to demonstrate a cause of action. If they fix or replace your engine, they are following the agreement they made with you when you bought the car. You can allege "diminution of value", because the...

Ford has a warranty on the engine. They will honor it. That is 100% of their obligation under law, unless you can prove they knew the pumps would fail in advance. Good luck with that. I'm not even a little bit convinced that the pumps are the problem. I think Ford will find that assembly errors...

I am absolutely certain that a drop test onto a concrete floor is not part of the oil pump testing protocol. BTW, "Weak" is not a technical term. I know you are convinced that the PM gear is inadequate. Nothing will change that. So I am going to stop trying. Take Ford to court. Try to prove...

I am an engineer. I work with exotic forged materials all the time. What concerns me is the automatic assumption that powdered metal is inferior. These sintered, heat treated parts are a mix of alloys with properties specifically chosen for the purpose at hand. There are literally millions of...

You are absolutely convinced that the pump is the problem. OK. I'm not. I believe just as strongly that these pump gears are being killed by foreign-object-damage, something they were never designed to handle. I know for a fact that Ford tested that engine for tens of thousands of hours under...

They buy the pump from a Tier 1 vendor. The vendor is tied to Ford's quality system and is 100% accountable for precision, QC tolerances, consequential damages, etc. The vendor has to show test results for strength and durability, often at 150% of rated load and for well beyond normal expected...