Turbo/catalytic converter failure after engine replacement

First my apology for this long explanation but felt sharing all the facts I know would help anyone responding.

My dealer replaced the “long block on our 2013 all wheel drive Flex. (99950 miles) Ecoboost motor 3.5 liter) We have the 100,000 Ford extended warranty which covered the engine replacement (long block). While the dealer had the car the mileage went past the warranty mileage. It is now past the warranty period.

The reason I took the Flex in, was it seemed louder in general operation. There was a rattle present on acceleration. It seemed to be performing OK, just more engine noise. There was no check engine light, just my “feel" for the car.

Now to the point I am communicating about, the turbo replacement and the replacement of the catalytic converters. When I got the car back from the engine replacement, the check engine light was on. I did not see it (it's low in the dash) until I was almost home and by then the dealer had closed for the day. I called the next morning to advise about the check engine light and the dealer Service Director asked how it was running. I said I did not notice any problems or any leaks on the ground. He felt it would be OK to operate the car. He said they did want the car back though for a follow up and would arrange for another loaner, which they did.

I took it back in and they went through the car. They did not have good news. They advised that they needed to replace the turbo -left side, plus the catalytic converters and that a right side half shaft. Estimated repair cost around $2550.00.


So here are my comments/questions: Would it be reasonable to conclude they would have discovered the bad turbo/converters while completing all of the diagnostic work to determine the engine was bad? It seems they would/should have completely gone through every component of the engine during the diagnosis, inspection, testing and subsequent cleaning and repair over the two and a half months they had the car?

For complete detail, here is a partial write up from the engine repair/replacement invoice:

*Check tsb’s “One found. IDS test polar balance, Relative comp verify with stethoscope noise cylinder 4, 5
*Noise stops with cylinder cancellation
* Perform section 303-00. Engine NVH diag. Engine oil, coolant OK. Inspect cylinder walls and combustion chamber with boro scope show bad wear.
* Remove motor for tear down inspection. Metallic debris in oil filter.
* Remove oil pan, rod caps, main caps, front cover, all 4 cams, left cylinder head, crank shaft, cams head journals, cylinder walls, pistons, rods all damaged from metallic debris.
*Replace long block,
*Switch over valve covers, intake, washout intake manifold, intercooler tubes, evacuate, fill coolant system, AC, top off trans,
* Road test, retest, pass, align car”

They gave me a loaner and called the next day to say I will be in the loaner for some period of time as they discovered that there were issues with the engine. That was 6/30/2018. I picked the car up 9/12/2018 at 6:41 pm.

As an FYI, just previous to the engine replacement, I had the car in on 6/19/2018 for a; preferred works package, new front/rear brakes, cooling system flush, brake fluid flush and quick lane multi- point inspection. I did mention the engine noise then too but the service rep forgot to write it on the service doc. That is why I had to go back on 6/30/2018, which is when the engine replacement process began.

I am not looking forward to the Repair cost (estimate) of $2,550.00 for new turbo/catalytic converters and half shaft repairs. As I already stated, I thought this would have discovered in all their inspections, diagnosis and repair during the two and a half months that they had the car for the engine long block replacement.

From my own research, I am told that there is a very high likelihood that the turbo and catalytic converters are related to the engine issues.

The dealer was good during this time and has always been easy to deal with for many years. They provided me a new dealer loaner vehicle for the entire time. They did their best to keep me informed. I almost had to relearn how to drive the Flex when I finally got it back!

Any guidance and suggestions appreciated.