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Join Date: Apr 2010
Location: Clinton, MS
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(1) Read your contract (not the info sheet "details") - look for exclusions and inclusions within the body of the contract. You state that EGR is included but there are several elements to the EGR system (EGR valve, EGR cooler, throttle plate possibly)...hold the company to the contract for which you paid...it is a LEGALLY binding document...breach of contract is a serious business offense and a lawsuit is an option - get the contract out and review it.
(2) Have the EGR cooler pressure tested. If the EGR cooler has not in fact ruptured (which would be validated by no loss of pressure during the pressure test or no bubbles produced if immersion is used) then your extended warranty company's assertion that the EGR cooler precipitated the problem is invalidated. Of course, if the headgasket has failed there is a good chance the EGR cooler is similarly compromised.
The parts to be replaced for a head gasket failure are directed by a series of TSBs...head gaskets may fail from a variety of causes including excessive pressure which may come from the introduction of coolant into the combustion chamber creating steam, overboosting from a malfunctioning turbo (although the pressure here is significantly less than with steam), cracks in the head itself, excessive fuelling from a faulty injector, etc.
There is more behind the post though I suspect. The warranty company is cited as indicating EGR is the cause (how could they substantiate a claim except by information provided to them unless they were allowed to perform an independent assessment). The dealer is cited as indicating the turbo was overboosting (which is recorded as a DTC in the PCM or through the Ford Rotunda Tool/WDS/other diagnostic data-logger). Aftermarket modification is often cited as a disqualifier but this too is not a universal exclusionary element...your aftermarket air filter doesn't provide proximate cause to a headgasket failure. (I am using this as an example, there is no information on vehicle production year or any modifications whatsoever)
Supporting documentation: used oil analyses, receipts for recall work performed, diagnostic results (WDS/Rotunda/etc.), truck mileage log (even if just a personal journal of mileage and fuel usage)...these provide substantive evidence for your maintenance and repair history - even if a lawsuit is not pursued (perhaps even helping to avoid that as a method).
Good luck with the warranty claim. If you are entitled then pursue - you bought a policy to protect against future expenditures - that is what you ought to expect. Notwithstanding, "caveat emptor" (let the buyer beware) - there are many unscrupulous insurance companies. Hopefully this is merely a case of hesitation on the part of the company in an effort to get you to provide full documentation...a technique that presumes - without merit - fraud. Let the company know in no uncertain terms how you do not appreciate this presumption...and remind them of the legal obligations within the contract (see again possible solution #1).
Good luck. Be patient.
P.S. Possible solution 3 is to demand refund of the cost of the warranty - not merely pro-rated as this is where negotiation from the company's perspective will begin.
Jonathan D. Howell
Lieutenant Colonel, U.S. Army
2005 EarthRoamer XV-LT (Ford F550)
"Americans Travelling America"
Last edited by howell_jd; 05-12-2011 at 08:11 AM.