Ford Ranger engine failure due to design flaw and poor workmanship

<p>In February 2014 IQ Oil purchased 2 x Ranger 4x4 single cab bakkies for service technician vehicles. The vehicles are meticulously cared for and serviced on the exact mileage only at approved Ford service centers. The vehicles have been serviced at Germiston Ford.</p> <p>In March 2016, when the vehicles were only 2 years old, one of them suffered oil starvation and a ceased engine. Investigation revealed that an engine lube filter had been incorrectly fitted during a service at Germiston Ford and the following day the oil leaked out while the vehicle was in use. Ford Germiston accepted responsibility for the engine failure and replaced the engine at their own cost.</p> <p>In October the same year, 2016, the engine in the same vehicle ceased again. This time due to a burst hose in the water cooling system. The vehicle gave no indication of overheating or low water level. Investigation revealed what we believe to be a design error whereby the water temperature sensor is right at the top of the cooling system which means that when the water leaks out of the system there is no water in the area of the sensor to transfer heat into the temperature sensor, therefore not causing a rise in temperature on the gauge inside the cab. The driver of the vehicle instead noticed the water temperature going all the way down to zero, at which point he pulled over immediately but it was too late. The engine was already severely damaged.</p> <p>The vehicle was towed back to Germiston Ford and a bill for R141,000 was presented to IQ Oil for a new engine. Ford Germiston and Ford South Africa have denied all and any liability. Ford Germiston who fitted the 1st replacement engine just 8 months prior to that have claimed it’s not their fault. The photgraph below suggests that the start of the tear in the hose is under the hose clamp and is most likely due to being poorly fitted, or forced, when the engine was replaced the previous time at Ford Germiston just 8 months earlier. Eventually the damaged hose gave in.</p> <p> </p> <p>Ford South Africa have claimed that the failure of the sensor to warn the driver in this case is not a design flaw. The fact that the sensor was unable to pick up the increased temperature when it was no longer submerged in water, apparently is not a design flaw. The fact that there is also no low water sensor in the water system is apparently also not a design flaw.</p> <p>2 failed engines would perhaps point to the driver of the vehicle. Perhaps he doesn’t take care of the vehicle the way he should. As is the case with so many company vehicles, they are seldom cared for by the driver the way they should be. I can put this concern to bed immediately. This driver is a technical person who understands the basics of machinery. He has been doing his job for 40 years. He has been with IQ Oil for 8 years. His previous company bakkie is an Isuzu KB250 which is still with the company today. The vehicle has 551,000kms on the clock and has never suffered any major breakdowns, has the original engine and gearbox, and is still serving the company well.</p> <p>Ford South Africa and Ford Germiston are completely disinterested in resolving this issue at this point.</p>