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Discussion Starter · #1 · (Edited)
Hey all, first time poster from Qld, Australia

Just looking to see if I am dead in the water, or if I have a leg to stand on in relation to my current issue. Apologies for the long winded post, but there are multiple moving parts to this, making it filthy

Background story
Monday 12th September I was cruising along at 80kph when all of a sudden my rear view mirror caught my attention. Mass amounts of smoke ploughing from the back of the car. Was a nice day so I had the windows down, and immediately noticed a ticking noise from the engine. Stuck it in neutral, coasted to the side of the road, turned if off and that was that up until this point.
No warning lights on the dash, coolant temp & levels fine, boost pressure fine, oil temp, pressure & levels all fine. No rough idle, no vibrations, nothing. RACQ plugged in their computer, no errors reported from the car
Then it started to get really darn nasty and upsetting

Firstly, Ford Australia towed it to a dealer even though I told them my warranty was with a different dealer (who was closer to my house). They told me that's fine, warranty will cover it anyway. Since then, I found out from my dealer it should have been towed to them for warranty (duh). Called Ford Australia, ended up speaking to the "Customer Experience Lead" for the country, who basically told me go away, and that I have to pay to tow the car to the right place. Even though Ford Australia, against my advice, towed it to the wrong place. So I have to pay to fix Ford's mistake. That's the first issue

Second. It has been 3.5 weeks and I only just found out that the engine is cooked. Just for reference also, their Ford computers also report no errors with the car. So the car thinks it is fine.... They haven't torn it down because that will incur costs, but the dealer it is with (not my warranty dealer) has recommended a new engine and new turbo for a total of $21.5k...

This is where it gets super dirty. It's a 2016, so it only came with the 3 year/100k Ford warranty. It is 6.5 years old, less than 89,000km on it, so still a baby. Meticulously maintained, all by the Ford dealer I bought it from. I bought it 2 years 10 months ago with a 3 year "platinum mechanical" warranty that cost me $1k. They told me at the time, everything under the sun is covered (warranty book basically confirms this) and regardless of cost, the car is covered because they serviced it an it is solid
When the car broke, I started looking at my warranty booklet, and it keeps referencing an "application page". Now I have a copy of every document they gave me during the sale, even documents from financiers I never ended up using, I'm pretty anal that way. So I called them asking what this "application page" is. All of a sudden I receive a page via email that includes a bunch of stipulations that I was never told about; e.g. set price servicing at $295 (I've been paying $400+ for scheduled servicing), max claim of $1k per claim, $3k over the course of the warranty (which seems absurd, paying $1k for that. Had I been told that, I never would have got the warranty as it is basically trash), and also a requirement to service it every 6 months or 10,000km to keep warranty intact (I have serviced it annually or 15,000km, as per the service manual and also as per the servicing department (the place that sold me the warranty)). This page also included the mandatory text that warranties need to include, outlined by the ACCC.

I saw this page in my email and immediately knew I had never laid eyes on it before, because it outlined stipulations that I had been told contrary, like claim limits etc. Then I noticed that the signature section of the page was empty. I never signed it, because I was never presented with it. But I have the receipt for the warranty and the warranty booklet that outlines what is covered (essentially everything)

So my questions are:
1) I believe the dealer should cover the entire cost of the repairs, because of the misinformation provided about the warranty (ie telling me what I wanted to hear to sell it, and not providing me with all the info), never mind me paying for it, but never signing the page that I was not presented with. Add to that the fact we are 24 days post-breakdown and they basically just fob me off. I think I've had 3 interactions with them after trying to get in contact basically every day
2) the car has never been thrashed, has been meticulously serviced, and only has 88,900km on it. It is my daily driver and the economy I have gotten over the ownership matches Ford's claimed urban economy, again proving I don't drive it like a lunatic. So regardless of warranty, with it being a likely manufacturing defect (the dealer who has it told me it's impossible I would have created the issue, it was likely a ticking time bomb), the dealer, or even Ford Australia, should cover repairs of it. I know it's 3.5 years outside warranty, but it is still below the 100,000km in that warranty, and going by consumer laws, I would assume everyone here would expect any kind of car (especially well maintained cars) to last more than 89,000km

If the dealer refuses to cover it, would I have a leg to stand on if I go through Fair Trade Qld/Consumer Law, or am I being biased toward myself with blind hope?

Oh, it also had it's head gasket replaced by my dealer, well prior to my purchase in 2019, as part of the Ford recall for the Focus RS. Wondering if this repair might have contributed to it in the long run

Again, apologies for the long first post, but if anyone has experience with similar issues or consumer law here, or even just opinions, they are all welcome

Thanks
 

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You need a bloodthirsty attorney who hates “corporate anything” to take your case. Otherwise you’ll pay everything out of your own pocket…. Either way, your car is down for likely a few years if not permanently dead.
 

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You need a bloodthirsty attorney who hates “corporate anything” to take your case. Otherwise you’ll pay everything out of your own pocket…. Either way, your car is down for likely a few years if not permanently dead.
You can't say that because he's in Australia not the US. Here with our consumer laws the overriding factor is "fit for purpose" so a vehicle outside warranty can still be covered for these sort of situations as "a reasonable person" would expect far more than this mileage from a cars engine. So the answer is fight them through your local consumer affairs and you should get at least most of the costs covered. The manufacturer just relies on the customer rolling over and not being willing to fight for their consumer rights .

Phil
 

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Any "aftermarket" warranty here in Australia is worth less than toilet paper. If thats what you are referring to, then I think all hope is gone, for any type of fix.
Ford are fuked either way, they will do anything and everything to get out of honouring warranty, so I wish you luck.
 

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That stinks. Sorry you’re having to deal with that.
Did they give you any info on what happened or why the engine is toasted? I know you said they didn’t tear it down yet.

There is a used engine and turbo on the marketplace of this forum listed for 1800 USD right now. I just saw it. I don’t know the seller -Just passing the info for some perspective or hope or whatever. You could probably charter a boat or a plane and come pick it up for less than $21k. Haha. Maybe.

Hopefully you’ll get in touch with the right person at Ford that can help. If not, you could cut losses and do a screaming custom build assuming you want to keep the RS.
Lemonade from lemons. Good luck, mate.
 

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I’m sure it’s easiest for Ford to say scrap the engine and replace it. Can’t necessarily fault them for that depending on what is wrong, but they should definitely tell you why it can’t be repaired.
I used to run a repair and service department at a bicycle shop. There were certain instances when a repair might technically be possible, but it was an iffy fix that likely wouldn’t last or be safe, so it was better for the shop and the customer to just replace a bad part rather than trying to repair it.
Granted, we were usually talking about $20 vs $20k.

I wouldn’t be surprised if your engine was something a local private shop might be able to repair though. The warranty debate is different, but thinking of getting the car running again, there may be more reasonable options.
 

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Anyone else think it's odd there were no error codes? Makes me wonder what the failure was. When my motor went, it was cylinder 3 blowing itself to bits and the dash lit up like a Christmas tree. $21K seems steep for factory replacement parts. I put a Mountune N1 longblock, precision turbo, act clutch and flywheel, and all the supporting mods (fmic, intake mani and plumbing, exhaust, etc.) all installed for about the same price. Shop around if your warranty isn't going to step up. The way the car market is now, these are tough cars to replace at this performance level per dollar. I saw it as an opportunity to build the car back stronger than it was.

Good Luck!
 

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I'm curious why you think the engine is blown. How loud is the ticking? Smoke from the exhaust doesn't always indicate a toasted engine and depending on what tick you're hearing, it could be normal. Once we had a failed turbo on one of our work trucks and the amount of smoke it threw out was insane. The engine was fine.

At a minimum I'd be taking the car to an independent shop to get their opinion.

As for the warranty, you've pretty much covered the bullshit of it in your original post.
 

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Discussion Starter · #13 ·
UPDATE: At around 4:15pm yesterday, I got my "F**k you" email from my dealer. They say they will cover $1k of the costs, the rest will be out of my pocket. I will fight the warranty with their management and also go consumer law route because the car was so well maintained and only lasted 89,000km, but we will see how we go
Worst case, I decide whether I do the following:
1) Cut my losses and sell it as it is
2) Get it towed back to mine and part it out over time to recover as much as possible
3) Take the $22k hit now, and then whatever loss in value when it comes to re-sale
4) Take it to an independent shop, get it stripped down, then see if it's more feasible to repair it, and possibly upgrade/forge it, take that financial hit and hope it doesn't devalue when it comes to re-sale in the future

I'm siding with #4 right now, as I'm sure a rebuild/upgrade will cost a good portion less than $22k, and I really have no urge to sell the thing, I damn well love it!! I just want it back, and functional

21K for New focus RS engine/Turbo+ install...smh....good luck OP
Insane, right?
That stinks. Sorry you’re having to deal with that.
Did they give you any info on what happened or why the engine is toasted? I know you said they didn’t tear it down yet.

There is a used engine and turbo on the marketplace of this forum listed for 1800 USD right now. I just saw it. I don’t know the seller -Just passing the info for some perspective or hope or whatever. You could probably charter a boat or a plane and come pick it up for less than $21k. Haha. Maybe.

Hopefully you’ll get in touch with the right person at Ford that can help. If not, you could cut losses and do a screaming custom build assuming you want to keep the RS.
Lemonade from lemons. Good luck, mate.
Nah, they haven't torn it down so I'm guessing they just decided it's easiest, and of course most profitable, to just replace everything, like @Wavlingth said below. It could be simple, it could be absolutely cooked, I'm in the dark. I will be asking them to perform a compression test and also remove a plug and shove a boroscope into the cylinder to check for any metal, scoring etc. If it's clean, that's a good sign. I'll stick the luck in my pocket, I'm going to need it!

I’m sure it’s easiest for Ford to say scrap the engine and replace it. Can’t necessarily fault them for that depending on what is wrong, but they should definitely tell you why it can’t be repaired.
I used to run a repair and service department at a bicycle shop. There were certain instances when a repair might technically be possible, but it was an iffy fix that likely wouldn’t last or be safe, so it was better for the shop and the customer to just replace a bad part rather than trying to repair it.
Granted, we were usually talking about $20 vs $20k.

I wouldn’t be surprised if your engine was something a local private shop might be able to repair though. The warranty debate is different, but thinking of getting the car running again, there may be more reasonable options.
I would say you're right about this, easier (and most profitable) to just replace. If consumer law doesn't side with the little man (me) then I think I'll be going down independent rebuild/upgrade routes

Anyone else think it's odd there were no error codes? Makes me wonder what the failure was. When my motor went, it was cylinder 3 blowing itself to bits and the dash lit up like a Christmas tree. $21K seems steep for factory replacement parts. I put a Mountune N1 longblock, precision turbo, act clutch and flywheel, and all the supporting mods (fmic, intake mani and plumbing, exhaust, etc.) all installed for about the same price. Shop around if your warranty isn't going to step up. The way the car market is now, these are tough cars to replace at this performance level per dollar. I saw it as an opportunity to build the car back stronger than it was.

Good Luck!
Mega weird man, like the car itself thinks it is fine, so odd. I appreciate the luck!

I'm curious why you think the engine is blown. How loud is the ticking? Smoke from the exhaust doesn't always indicate a toasted engine and depending on what tick you're hearing, it could be normal. Once we had a failed turbo on one of our work trucks and the amount of smoke it threw out was insane. The engine was fine.

At a minimum I'd be taking the car to an independent shop to get their opinion.

As for the warranty, you've pretty much covered the bullshit of it in your original post.
I was thinking possibly turbo as well. I'm only going by what the shop said. But I will be getting them to do some tests as I mentioned above to get more of an idea of it's condition, then I'll fight the warranty and consumer law

JEE ZUSS!! What a **** experience (so far)! My initial reaction was what FORZDA2 said, but I'm sure LuckyPhil has the right advice for Down Under! Sincerest wishes on getting it sorted;cheapest (to you); soonest! (y)
I appreciate the good wishes man, I'm going to need them

As you’re in QLD if Ford doesn’t fix under warranty get in touch with Ash at RS Tech Australia. Facebook လောဂ်အင်ဝင်ရန် Can’t recommend enough. High attention to detail and does everything to very high standard. Knows the platform inside out and does engine rebuilds too.
I was about to stick up a post (might still do it) about engine rebuilders in QLD, so seeing this is mighty helpful. Checked out his FB and it's insanely cool, will definitely contact, so I really appreciate the input my man!
 

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If you can afford the time off the road then fight them. I've won 3 consumer rights claims from motorcycle manufacturers over the years. Parting it out would be a bad financial choice. A forged short block would be good if you can re use the head and other components, maybe a Mountune short block imported?
Of course your issue with regards to what actual cause was is complicated by the fact you bought the car second hand. Not an issue consumer claims wise if it's got great service history but sometimes the "hurt" is done by a previous owner a long time before the ultimate failure occurs.

Phil
 

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Discussion Starter · #15 ·
If you can afford the time off the road then fight them. I've won 3 consumer rights claims from motorcycle manufacturers over the years. Parting it out would be a bad financial choice. A forged short block would be good if you can re use the head and other components, maybe a Mountune short block imported?
Of course your issue with regards to what actual cause was is complicated by the fact you bought the car second hand. Not an issue consumer claims wise if it's got great service history but sometimes the "hurt" is done by a previous owner a long time before the ultimate failure occurs.

Phil
That message started out motivating me and ended up demotivating me, but they are valid points and I'm glad to hear consumer rights has proven valuable to you over the years! I've got a couple of motorbikes to get around on so not having the car is more inconvenient than it is critical, thankfully
You're right that it could have been caused by the previous owner, but my argument to that (which seems logical but is likely invalid) is the fact the the fuel consumption on the car has always been within the Ford specs for urban etc. You would think if it's been ragged, the consumption would be way up. On top of that, I have done 45,000km on the car with 0 issues, so it seems just as likely to be a manufacturing fault than fault caused by previous owner. Hard to tell/prove

I'm going to fight the crap out of it like you said, but also prepping myself for worst case so that if it fails, I am not back to step 1, I have a clear path (rebuild/mod) ahead 🙂
 

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Hey all, first time poster from Qld, Australia

Just looking to see if I am dead in the water, or if I have a leg to stand on in relation to my current issue.

No warning lights on the dash, coolant temp & levels fine, boost pressure fine, oil temp, pressure & levels all fine. No rough idle, no vibrations, nothing. RACQ plugged in their computer, no errors reported from the car
Called Ford Australia, ended up speaking to the "Customer Experience Lead" for the country, who basically told me go away, and that I have to pay to tow the car to the right place. Even though Ford Australia, against my advice, towed it to the wrong place. So I have to pay to fix Ford's mistake.

Oh, it also had it's head gasket replaced by my dealer, well prior to my purchase in 2019, as part of the Ford recall for the Focus RS. Wondering if this repair might have contributed to it in the long run
So, to summarise:
(1) You bought a second-hand 2016 Focus RS that had done 43,000 km (27k miles) in November 2019
(2) You bought it without Fords manufacturers warranty, but paid for a dealership warranty instead
(3) You drove it for almost 3 years and put another 46,000km (29k miles) on the clock before the engine gave out

What mods were on the car when you bought it, and what mods have you yourself put on the car? Is the car tuned, and if so, by who?
 

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Discussion Starter · #17 ·
So, to summarise:
(1) You bought a second-hand 2016 Focus RS that had done 43,000 km (27k miles) in November 2019
(2) You bought it without Fords manufacturers warranty, but paid for a dealership warranty instead
(3) You drove it for almost 3 years and put another 46,000km (29k miles) on the clock before the engine gave out

What mods were on the car when you bought it, and what mods have you yourself put on the car? Is the car tuned, and if so, by who?
Essentially correct, as well as being serviced at minimum every 15,000km, if not every 7,500km

It was sold to me by the dealer with an ETS intercooler w/piping, ETS air intake, Turbosmart BOV all from Car Mods Australia. Also a 3" downpipe with cat from Elite Exhausts. All of these were purchased in December 2017 with a tune by ProFile Autosports performed a few days later, 20th December 2017. Power up from 257kw to 274kw

I have not modified anything on top of that myself
 

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OP,
I’m just throwing this out there for the sake of troubleshooting and exploring possible culprits—

I just saw your introduction post and the pics of your super clean RS. -Looks awesome btw.

Is it possible that you fried something cleaning the engine bay? Had you just detailed it?
I noticed a hole in the top of the battery cover. Don’t now how that could cause an issue, but just thinking of how it bonked out without a violent explosion or loud noises or anything. Sounds like it started smoking and fizzed out. How loud was the ticking?
If you fried a coil pack: I think it would have thrown a misfire code at least, and you probably would have felt it, but could it have been something else in the electrical system?
Also, I think I recall an engine cleaner I’ve used in the past (“Gunk” I believe) mentioning that the engine could smoke while it burned off. I may be remembering wrong.

Anyway, just wondering if maybe something in the engine bay got compromised with a pressure washer or something.

Alternator?

Also,any idea if it’s still holding oil?

If the dealership are being difficult, I’d get it back in your possession so you can troubleshoot it yourself or with an Indy. I don’t know how the consumer laws, etc… are handled over there, if you need to leave it in limbo at the dealer for some reason, but I’d certainly feel better with a second opinion or after I’d had a chance to look it over again myself - if it was my car.

Best of luck with it!
 

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Essentially correct, as well as being serviced at minimum every 15,000km, if not every 7,500km

It was sold to me by the dealer with an ETS intercooler w/piping, ETS air intake, Turbosmart BOV all from Car Mods Australia. Also a 3" downpipe with cat from Elite Exhausts. All of these were purchased in December 2017 with a tune by ProFile Autosports performed a few days later, 20th December 2017. Power up from 257kw to 274kw

I have not modified anything on top of that myself
Ok.
I see from the pictures of the engine bay that you also have a Radium catch can on the PCV side.
When was the last time you emptied that, or do you normally leave that to the dealership?

I’m just wondering if that catch can is full of liquid from never being emptied. That would possibly create an increase in crankcase pressure while cruising (and at idle) which would cause smoke without throwing any codes.

Is that hypothesis too silly @lucky phil? Would a Ford dealership tell you to buy a new engine and turbo when all you needed to do was empty the catch can?
 

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Just my 2cents, but I think I would probably go down the route of #4 if I needed the car back sooner rather than later. My thoughts are that the dealer warranty situation is an absolute P take!!! That said I know in the UK also the extended warranty offered by a third party can be hit and miss - so I am on the fence as to whether you hold out and fight or put it behind you. I suppose the Dealer is hoping you just take it on the chin, or maybe sold it knowing it was useless. Whilst I also appreciate going to the dealers for cars they produce etc., I actually think in the case of something like the RS I prefer an independent third party performance specialist to do the work, but this is just me. There is every chance they will be able to fix for less than the Ford quote, or even offer options Ford wont e.g. rebuilding using an engine from a wrecked vehicle e.g. rear end write off. Whether you would want to do that, of course is your choice, but I feel for you mate. $21k is just outrageous though.

I appreciate no matter the choice, it's probably going to leave you out of pocket, but hopefully you get it back on the road and can try forget about it all as soon as possible!
 
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