Ford settles class action suit over defective Super Duty engines

Article by Anita Panait, on October 27, 2013

Ford Motor Co. has reached an agreement to settle a class-action lawsuit over allegations that it sold defective diesel 6-liter V-8 engines in its 2003-07 Super Duty pickups and E-series vans. The engine, built by Ford's former diesel engine supplier, Navistar International, encountered several issues with the fuel system, turbochargers and other major components.

According to the deal, any purchaser and lessee of any 2003-07 Ford vehicle fitted with the diesel engine in the United States is covered if its exhaust gas recirculation (EGR) cooler and EGR valve, oil cooler, fuel injectors, or turbocharger was repaired, replaced or adjusted prior to 135,000 miles or six years. Each part is also provided with a reimbursement limit.

The settlement also calls for a reimbursement if a class member paid a $100 deductible more than once for repairs under the five-year/100,000-mile engine warranty. The carmaker will reimburse $50 each for the second through fifth deductible paid, up to a limit of $200 for four deductible payments.

The settlement agreement resolves dozens of class-action lawsuits against Ford, allowing owners to claim between $50 and $825 in reimbursement for post-warranty repairs to their engine and engine parts.

The relationship between Ford and Navistar came to an end no thanks to poor engine quality, high repair costs and declining customer satisfaction. Ford used Navistar’s Power Stroke engine in its F-Series from 1994 to 2010, when the carmaker replaced the powerplant with a new 6.7-liter diesel V-8 that it developed in-house.

The Power Stroke family of diesel engines has been used in trucks produced by Ford Motor Co. since 1994. Aside from the Ford F-Series -- including the Ford Super Duty trucks – Power Stroke diesel engines are also used in the Ford E-Series.

Ford first employed Power Stroke engines in 1994. The first Power Stroke name - the 7.3-liter Power Stroke V8 mill – is essentially a re-branded unit produced by Navistar International. Basically the Ford version of the Navistar T444E turbo-diesel V8, the 7.3-liter Power Stroke V8 served as the replacement for the 7.3-liter IDI V8.

In 2001, the 7.3-liter Power Stroke V8 was replaced by the 6.0-liter Power Stroke diesel V8 engine, also known as the VT365. The 6.0-liter Power Stroke VT365 engine is used in mid-2003 model year Ford Super Duty trucks until 2007 model year. It was also used in 2003 to 2010 model years Ford E-Series vans/chassis cabs. Prior to 2005, this V8 engine delivered 325 hp (242 kW) and 560 lb.-ft. (759 Nm). In 2005, the torque level was hiked to 570 lb.-ft. (773 Nm).

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