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Blackyote's New Long Block Adventure

blackyote_317

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Warning: This is a long synopsis of the nearly 2 month saga that ended in a brand new long block for my 2017 GT.

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I bought my 2017 Mustang GT base 6 speed in September of 2017. Starting sometime in spring 2018 I started noticing a rattling type noise at low RPM. Usually 1800-2000 RPM. It would die down a bit after the car had been running for a while and was fully warmed up but wouldn't go away completely. The car seemed to run perfectly other than the noise but I brought it to the dealer anyways because warranty. I brought the car in on May 8th with ~12k miles.

I thought the rattling noise was in the clutch because it often happened during shifts (hell, I even posted about it in the transmission section on here) or maybe a heat shield even. I definitely had no idea what I was getting into though I had heard of piston slap and figured that was a possibility. I even mentioned it when I dropped it off. Well, turns out that was part of the issue but the noise sounded lower to me. Like, in the transmission area but my exhaust is loud so it is hard to pinpoint.

After a day or two of them having it, I was told they had tracked a noise to the passenger side valve cover so they pulled that. They eventually found some scoring on the cam caps. We were now to the point that Ford was going to do a cost cap analysis on what should be fixed. Thankfully, the dealer kept digging into the engine because they didn't like the idea of what was essentially a brand new engine being rebuilt on the bench.

At some point along the way they pulled the pistons and saw scoring along the cylinder walls indicating piston slap. On June 1st (about 3 weeks in), a short block was approved. Ford said no metal had been transferred so it didn't affect the life or integrity of the engine. They were waiting on a head gasket which was on backorder so they put in an emergency request for that. No ETA could be given.

I started calling Ford corporate at this point and trying to push for a long block. I really didn't get anywhere with that. They kept pointing me back to the dealer. I was beyond frustrated because no one could give me a timeline on the head gasket and I wasn't even happy with the short block as a solution at this point. I really thought I deserved to have a long block on such a new engine with this many problems. I didn't buy this car to have a rebuilt engine within a year...

I kept getting the runaround on a timeline. Finally, I was told the part(s) they were waiting on were backordered for at least another month. When the dealer told me this, I told them that was unacceptable. They were pulling my leg a little bit at this point and then informed me that they had in fact pushed back on Ford about this and a long block had been approved. This was about June 12th so almost 5 weeks in. The long block was to be in the next week. It made it, but it was of course the next Saturday :mad:

Anyways, they ended up getting the engine in the car and I was slated to pick it up the following Friday (June 29th). The day I was supposed to pick it up, my buddy calls me and tells me they replaced the windshield because it had a crack in it. I told him that it sure as hell didn't when I dropped it off. They told me it was likely due to the extreme heat we've been having. They apologized profusely but had it repaired without a fuss and on their own dime so I didn't have too much to complain about. It did push pickup back to the next morning to let the glue settle. I drove it about an hour from the dealer back to my place on Saturday with no issues that day and took it for a drive later too. Everything seemed to be perfect.

On Sunday, the day after picking it up, I had a 'service charging system' light pop up on me several times and then immediately go away. The voltage seemed normal - bouncing between 12 and 14 volts as the alternator kicked on and off. I took it back home and pulled the battery cables and then re-attached. Haven't had that message pop up again. I told the dealer this happened and that if the light comes on again, I will bring it back to them. Hopefully a loose connection was all it was. It didn't do it this morning on the way to work.

After getting my car back with a brand new long block, here are my thoughts. Ford corporate frustrated the hell out of me with their long process and being awful with communication. I couldn't get ahold of anybody who had any authority or knowledge of the situation and hearing of their short block solution was horseshit in my opinion. It worked out eventually and I got the long block, but that was dumb luck and not good customer service. I was lucky and worked with a very good dealership but the car was torn apart for a long time which ended in a cracked windshield and potential issues with the charging system. Or who knows what else honestly. Time will tell. I'm not doubting their ability but putting a car together in a shop isn't as precise as an assembly line. I'm very happy with the dealer but frustrated in Ford's slow attitude towards fixing a customer's car. I will demand a buy back if it goes in for anything longer than a few days at this point. I didn't get to that point in this process because

So here are some components to this story that some may be interested in:

1) The car had a VMP tune on it with PMAS intake and exhaust. Basic bolt on stuff. Yes, I was concerned about a claim being denied but it never even came up. No, I don't know how or why. I didn't try to cover it up in anyway. I did revert it back to stock tune and airbox before bringing it in but that was just to eliminate variables when it went in. I just let the dealer work it out and they were excellent and definitely wanted to do right by me.

2.) The dealer I brought the car to for work is the dealer I bought my car from and has two of my very close friends on their sales staff. One of them was sort of my informal liason with the service dept. I also traded in a 2016 F-150 for the Mustang so I've been very good to Ford recently.
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PoppinJ

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Its a painful process for sure. I wish you had the scope pictures of the cylinder damage, that would be cool to see. Mine was in the shop for 1 1/2 months waiting on backorder parts, its super frustrating. Anywho, if you ever have another problem you are already eligible for a lemon law buyback. Im assuming the car is under 18months old and its already been in the shop for over 30 days. Ford gave me the complimentary 75K warranty for my troubles.....but the car still makes the rattle sound sooooo.... No engine mods for me. Glad it all worked out in the end. What rental car did they give you?
 
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blackyote_317

blackyote_317

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I do have a picture of it somewhere but I couldn't find it when I was typing this up. Might need to have my buddy send it again.

Yeah, it would be eligible for lemon law. I wouldn't do it for something silly and minor but any other major issues and I'll be doing that. I don't plan to tune this one anytime soon that's for sure.
 
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blackyote_317

blackyote_317

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haha sorry. Hard to keep track of all of it. I honestly thought it was clutch or transmission related when I brought it in. I'd heard of the engine rattle, etc but I didn't think that's where I was hearing the noise from. I did mention it to them as a possibility though when I brought it in.
 

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Mhjr74

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Do you know what the horsepower and torque are with the long block?
 

TrevorGT

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If I were you, I’d just be happy as hell that they covered you with a tune. My purchasing dealer said the pp2 kit would void the warranty and the 2nd dealer just wanted nothing to do with it. Lol
 
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blackyote_317

blackyote_317

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Do you know what the horsepower and torque are with the long block?
Well it should be just a standard gen 2 coyote so rated for 435 hp / 400 tq is my assumption. Too bad they didn't stick a gen 3 in there haha

If I were you, I’d just be happy as hell that they covered you with a tune. My purchasing dealer said the pp2 kit would void the warranty and the 2nd dealer just wanted nothing to do with it. Lol
I was definitely concerned and that's why I kept calm and quiet for a long time during the process. I might have had some help from the dealer getting it pushed through since I am actually friends with people who work there. I don't know that for certain. To be fair, I've never done anything stupid in my car. It's never been revved to 8k or anything like that. The piston slap is a mechanical issue unrelated to the tune. PP2, if installed by a Ford dealer, should definitely be covered is at least my understanding. Besides the fact it seems to be a decent kit, the fact of uncomplicated warranty claims is on of the draws people have to it.
 

NoVaGT

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Do you know what the horsepower and torque are with the long block?
A long block is just a (more or less) complete engine. A short block is generally just the block and rotating assembly, maybe a few other bits and bobs.

So.....your question is confusing.
 

wildcatgoal

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Ford's ability to drag along a warranty claim such as this never ceases to amaze me. If the dealer says it's broken, and they are trained Ford repair technicians, replace it now. If you can't trust your dealers, then you need to think differently about training and goal setting, not make customers wait ages to get the car they're paying for back working.
 
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blackyote_317

blackyote_317

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Ford's ability to drag along a warranty claim such as this never ceases to amaze me. If the dealer says it's broken, and they are trained Ford repair technicians, replace it now. If you can't trust your dealers, then you need to think differently about training and goal setting, not make customers wait ages to get the car they're paying for back working.
Yeah, they really drug it out. Head gaskets for a new engines should not be out of stock for any significant period of time. It's the same supply issue with the forks for the 2018 mt82. Crazy.

My main frustration is that I couldn't get anyone at Ford to talk to me. I kept getting the runaround by some guys who almost certainly were outsourced and physically somewhere on the other side of the world.

I guess I should be happy because in the end, I got the repair completed and my car back. Others haven't been so lucky.
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