cekkk wrote:
So far the one concern I have is the fuel pump that was raised in the first replies. What was the problem, total failure, partial fuel starving?
There has been many different types of issues. The greatest issue is that the pump has no tolerance for water in fuel. That's why the fuel filter setup is pretty robust on the Fords (I personally wonder how GM gets away with only 1 fuel filter as RAM and Ford both use 2). I'm not sure how much water needs to get into the fuel before it starts messing up the pump, but it isn't much. Standard procedure when checking the pump is to pull the flow control valve out and see if there's any rust developing on it. There have been plenty of individuals that did have rust on this valve, and Ford surmises that if there's rust on the valve, water was in the fuel, therefore bad fuel is the cause of the failure, not an engineering issue. So therefore, the owner is left flipping the bill (this is what lead to the Ford not honoring the warranty comment). However, the question that brings up is how does fuel get past the filters? In many cases, the owners that had this issue that posted online almost unanimously state that they never received a water-in-fuel warning in which the pump has sensors to detect. So take it for what it's worth.
There have been owners that dumped some DEF into the fuel tank on accident and ran their truck and had catastrophic failure as well. Very expensive mistake to make if your insurance doesn't pick it up. So some issues are user caused some aren't.
The primary issue is the failure mode of the pump. On the older Bosch CP3's and previous pumps the manufacturers used, failure of the HPFP would send shrapnel back into the tank. The new CP4 pump sends shrapnel into the fuel lines and injectors. So if the pump dies, it takes all the injectors with it.
This was one of the aspects that made me shy away from Ford, that and my wife subjectively did not like the interior as much as another competitor.