Catalytic Converter Failure

[Robert J]

The story begins in July 2023. My 2018 F-150 shows a check engine light at 70,380 miles. I take it to my dealer (Gordie Boucher Ford Thiensville WI) and they run the $150 scan and determine that the left catalytic converter is bad. The warranty on the converter runs to 80,000 miles so it turns out the diagnostics and replacement of the converter is covered under warranty so no cost to me. I wasn't aware that there were two converters on the truck and of course they won't replace the right one at that time because diagnostics don't indicate it is bad. Now roll the calendar ahead to April 2024 and once again a check engine light reappears. Well now the diagnostics test is up to $175, and my truck has 80,930 miles on it so past the 80,000 warranty range on the converter. I told the service advisor (Angie) I am guessing it is the right converter and she tells me she will go to bat for me with Ford. They call me to inform me that it is indeed the right Catalytic converter and gives me a cost of over $2,300.00 to replace it!! I of course balk at that cost and she asks me if I have an extended warranty. She knows full well I don't as I have all the service work performed at their dealership. So, the talk about going to bat for me with Ford is no longer there and I called her on that. She then states she will talk to her Service Manager to see what they can do.

 

He called me and stated he will apply for the Ford Good Will Program. I never heard of this program before and after researching it I am not finding much information explaining the program. Well, the game continues and about a week later I receive a call from the service advisor telling me Ford approved it and I get to pay 60% of the cost while they supposedly cover 40%. An appointment is made for April 22,2024 at 8am and I received a call telling me the part is lost in transit. I received a follow-up call 20 minutes later stating they located the part, and it will be delivered Tuesday morning. I told her to call me when you have the part in hand, and I will then make an appointment. That happens and I take the truck in on April 26, 2024. The repair is completed, and I receive the paperwork showing just my payment of $1319.11 with sales tax. No indication whatsoever what Ford's payment is.

 

I have been driving Fords since 1990 and am now pretty disgusted with them. I am seriously considering selling my truck and buying a Toyota Tundra. 

[Chrisgb]

This seems like a pretty straightforward episode to me. "Angie" would not know offhand if you had an extended warranty, only a Ford ESP warranty or a third party extended warranty purchased at that dealer would be visible to her. She eventually did go to bat for you, albeit with a little prodding, and the svc mgr applied for and obtained the good will program.

 After a logistics hiccup, the part arrives. They install the cat, and charge you $1319.11 incl tax 5.5% +/-, or about $1,346 (I live in WI too). A quick Google search for an original equipment right side catalytic converter shows a retail price of $1,491.43 for just the part. https://www.oemford.parts/oem-parts/ford-catalytic-converter-jl3z5f250b?origin=pla  So your cost seems very reasonable; about 54% of the $2,300 Angie quoted you originally. 

 Correct me if I'm wrong, but you didn't mention if there was a Ford payment disclosed for the left cat replaced under warranty. In my experience with Ford, GM, and Chrysler (now Stellantis) vehicles I've owned, the cost of factory or dealer warranty work is never disclosed, either left blank or "No Charge." IMO, you were treated fairly and I would buy and service from that dealer. The Tundra is a very good truck as well. If you decide to buy one I hope you will be treated as fairly as you were at Gordie Boucher Ford.

[fordmantpw]

On 4/27/2024 at 10:14 AM, Robert J said:

The story begins in July 2023. My 2018 F-150 shows a check engine light at 70,380 miles. I take it to my dealer (Gordie Boucher Ford Thiensville WI) and they run the $150 scan and determine that the left catalytic converter is bad. The warranty on the converter runs to 80,000 miles so it turns out the diagnostics and replacement of the converter is covered under warranty so no cost to me. I wasn't aware that there were two converters on the truck and of course they won't replace the right one at that time because diagnostics don't indicate it is bad. Now roll the calendar ahead to April 2024 and once again a check engine light reappears. Well now the diagnostics test is up to $175, and my truck has 80,930 miles on it so past the 80,000 warranty range on the converter. I told the service advisor (Angie) I am guessing it is the right converter and she tells me she will go to bat for me with Ford. They call me to inform me that it is indeed the right Catalytic converter and gives me a cost of over $2,300.00 to replace it!! I of course balk at that cost and she asks me if I have an extended warranty. She knows full well I don't as I have all the service work performed at their dealership. So, the talk about going to bat for me with Ford is no longer there and I called her on that. She then states she will talk to her Service Manager to see what they can do.

 

He called me and stated he will apply for the Ford Good Will Program. I never heard of this program before and after researching it I am not finding much information explaining the program. Well, the game continues and about a week later I receive a call from the service advisor telling me Ford approved it and I get to pay 60% of the cost while they supposedly cover 40%. An appointment is made for April 22,2024 at 8am and I received a call telling me the part is lost in transit. I received a follow-up call 20 minutes later stating they located the part, and it will be delivered Tuesday morning. I told her to call me when you have the part in hand, and I will then make an appointment. That happens and I take the truck in on April 26, 2024. The repair is completed, and I receive the paperwork showing just my payment of $1319.11 with sales tax. No indication whatsoever what Ford's payment is.

 

I have been driving Fords since 1990 and am now pretty disgusted with them. I am seriously considering selling my truck and buying a Toyota Tundra. 

 

What are you upset about?  They fixed it as they said you would at the cost they quoted you.  Seems like they upheld their end of the bargain, no?

 

Why would you sell your truck?  It's got 2 new catalytic convertors in it, so it should be good for a while!

[akirby]

Because people don’t understand warranties.  They refuse to pay for the extended warranty then get pissed off when the company won’t give them free coverage.  It’s like going to McDonald’s and buying a quarter pounder by itself then later demanding they get fries and a drink for free,  

 

The bigger question he should be asking is what’s wrong with his engine?  Cats do t just go bad in 80k miles.  There is a misfire somewhere and that’s probably destroying the new cats as we speak.

[Flying68]

14 hours ago, akirby said:

Because people don’t understand warranties.  They refuse to pay for the extended warranty then get pissed off when the company won’t give them free coverage.  It’s like going to McDonald’s and buying a quarter pounder by itself then later demanding they get fries and a drink for free,  

 

The bigger question he should be asking is what’s wrong with his engine?  Cats do t just go bad in 80k miles.  There is a misfire somewhere and that’s probably destroying the new cats as we speak.

Cats are like all other parts.  Had one replaced on the Expedition at around 78,000 miles under the emissions warranty.  Occasionally a part fails due to manufacturing defect.  I am not worried about another one, but I also have a 7/125 Ford Premium care plan, so if another fails, I am still good (at least for another 2 years and 40,000 miles).

[akirby]

48 minutes ago, Flying68 said:

Cats are like all other parts.  Had one replaced on the Expedition at around 78,000 miles under the emissions warranty.  Occasionally a part fails due to manufacturing defect.  I am not worried about another one, but I also have a 7/125 Ford Premium care plan, so if another fails, I am still good (at least for another 2 years and 40,000 miles).

I could see one failing due to a defect but not 2 on the same vehicle.    It’s certainly possible that he got two defective ones but I would say the probability is low.