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Bent Exhaust Intake Valves!?!? *UPDATED!!!*

5.9K views 37 replies 20 participants last post by  lourenco  
#1 ·
You probably won't believe this....but I traded in my 2000 Focus Sedan (hence "snobrdrdans_sedan")like 2 months ago and got a 2003 Focus SVT ZX5 loaded. It was used with about 9300 miles on it and I got it for under $13K and it was in mint condition. SO I just started putting my mods on it. Got the YRFO update, then put on a Progress rear sway bar, rear engine mount, Steeda short ram intake, MBRP exhaust, Steeda short shifter and I just put my FocusSport UDP on this past Monday. Car was running awesome that day!!

So Monday night I went out with my buddy and I'm going on the free way and accelerating. I missed 4th gear going from 3rd and the engine over revved or something. Instantly...the check engine light came on and the oil pressure gauge dropped. I was just like...oh great. There wansn't oil leaking or anything and it was still driving. So we got off the freeway and checked it out. Nothing to the eyes to notice. It sounded like a diesel engine on start up. SO I was trying to make it back home and get my other car and then the car just died doing 50mph. Called Ford to come tow it and they didn't end up towing it that night. The next morning they did come and get it off the side of the road I found out.

So blah blah blah, the dealer looks at it and the guy calls me back and says "the exhaust intake valves are bent" and that's "impossible!" to happen. And that Ford denied it for warranty and that the car is gonna need a motor! I'm like umm okay!?!? Then he asked me what else I had done to it and I told him the exhaust, intake & pulley (to the motor). Then he said the motor must have been at 10 or 11,000 RPM to bend the valves. I'm like it has a rev limiter though and I wasn't racing it. So he said they have to call in their Ford Rep. to come in and look at it and see what he says. But as it stands right now it's not covered under warranty with 10,300 miles on it. He even tried to hint that I might have reprogrammed the computer and removed the rev limiter or something.

So anyways I was bummed out and thought I'd share that story. Just seems ridiculous. I didn't break the engine on purpose or anything! I'm not totally familiar with the mechanicals of the engine and how it could have happened but this totally sucks. And them saying that my few modifications might have caused it is ridiculous too.

Any ideas on what I can do if they deny it for warranty??
(Other than drop another motor or V-8 in it!)
Like who could else could I talk to about it??
THANKS
 
#2 ·
Re: Bent Exhaust Intake Valves!?!?

Well, in this case it will be hard to prove your case. They have a pretty good point to deny warranty, seeing that you have mods on your car. Its easy for them to say that the motor was not built to handle the things you did to it.
What do you mean, "missed" going into 4th? Did you mean you where trying to go into fourth when you where redline in 3rd, but went into 2nd instead? I put my money on it thats what happened, and the computer will show if that happened, because I have done it, and my tech laughed at me because I had an "over rev" code. Thats exactly what would happen to if you where redline in 3rd and went into second on accident...bye bye valves. Good luck.
 
#4 ·
Re: Bent Exhaust Intake Valves!?!?

If you miss shift the rev limiter is not going to do anything, so that point is invalid.

I do hope you get it all worked out though.
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It depends on how he "mis-shifted." If he grabbed 2nd then you're correct. If he just hit neutral then the rev limiter will not let you blow the engine. And, grabbing 6th does nothing except make you bog.
 
#5 ·
Re: Bent Exhaust Intake Valves!?!?

If you miss shift the rev limiter is not going to do anything, so that point is invalid.

I do hope you get it all worked out though.
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It depends on how he "mis-shifted." If he grabbed 2nd then you're correct. If he just hit neutral then the rev limiter will not let you blow the engine. And, grabbing 6th does nothing except make you bog.
Well, yeah. I thought that was a given. Seems pretty certain he went into second and then it went bad on him.
 
#6 ·
Re: Bent Exhaust Intake Valves!?!?

It had to be that he went into second. If thats the case, which is the only explanation I can see, then you just have to take the hit. Unless you are into fraud, otherwise it is totally your fault.
 
#7 ·
Re: Bent Exhaust Intake Valves!?!?

If you miss shift the rev limiter is not going to do anything, so that point is invalid.

I do hope you get it all worked out though.
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It depends on how he "mis-shifted." If he grabbed 2nd then you're correct. If he just hit neutral then the rev limiter will not let you blow the engine. And, grabbing 6th does nothing except make you bog.
Well, yeah. I thought that was a given. Seems pretty certain he went into second and then it went bad on him.
This is at least the 4th case of someone missing 4th and hitting 2nd. I'll never understand this one. I know the gates are close, but wow...

The mods had nothing to do with this incident. However, the dealer will take the easiest option out, which coincidentally will be the hardest for you to prove otherwise. Good luck, this really sucks!

Edit: Oh, saw the short shifter. That's the kicker.
 
#8 ·
Re: Bent Exhaust Intake Valves!?!?

If you never had it happen to you, you are not driving hard enough
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I grabed first from fourth under heavy breaking. Luckly I was fast on the clutch and I'd guess it only saw 8~9k. (its a good reason not to shift like a drag racer)
 
#9 ·
Re: Bent Exhaust Intake Valves!?!?

Yeah, a missed shift and bent valves aren't going to be covered under warranty, so you might as well face reality and just try to learn from this (hard way, I know... join the club). The new KA20 motors from Honda have ridiculously soft valve springs and those guys bend valves like it was cool. Fortunately for them though, Honda came out with some new springs and is quietly replacing them as people blow up (Honda actually issue a recall? Hell's no... you want the good stuff, you have to blow your [censored] up first
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). So at least they have an argument. A missed shift is considered "driver error" and you're at the mercy of a dealership *maybe* hooking you up, but its highly doubtful.

Sorry there's no better news.
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#10 ·
Re: Bent Exhaust Intake Valves!?!?

Well I just wanted to see what you guys all had to say about my little "mishap."
You are all correct though. I grabbed the shifter knob at a wrong funny angle and was trying to pull it back into 4th and I was at the angle for 2nd instead. Don't ask me how or why but I grabbed the shifter wrong, and thought I had an easy shift.
So yes, I know, very stupid.

So more than likely I'm screwed, huh??
I'm still waiting to see what the Ford Rep. says though b/c he still hasn't looked at it.
Is the only option to buy another SVT Focus motor??
Anyone ever price one out?? I'm guessing $3,000-5,000.
Any ideas would be more than helpful!

THANKS again.
 
#11 ·
Re: Bent Exhaust Intake Valves!?!?

Well I just wanted to see what you guys all had to say about my little "mishap."
You are all correct though. I grabbed the shifter knob at a wrong funny angle and was trying to pull it back into 4th and I was at the angle for 2nd instead. Don't ask me how or why but I grabbed the shifter wrong, and thought I had an easy shift.
So yes, I know, very stupid.

So more than likely I'm screwed, huh??
I'm still waiting to see what the Ford Rep. says though b/c he still hasn't looked at it.
Is the only option to buy another SVT Focus motor??
Anyone ever price one out?? I'm guessing $3,000-5,000.
Any ideas would be more than helpful!

THANKS again.
Check ebay for motor.
Ive done what you did about 7 times. You dont happen to have the steeda sts do you?
I would say, be honest with the rep. Hopefully they are nice, and understanding. I would put my money on not. But, you never know. It happens, and with those mods the valve would not bend. If you where stock, the same exact thing would have happened. But, youll never know for sure if it would have, because the motor is not stock. You have changed all kinds of variables on the motor, so Ford is free and clear if they try and weasle their way out of it. Just like they will. Besides that, I just dont see how they would pay for your mistake. I hope Im proved wrong. Please keep us updated.
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Good luck once again.
 
#12 ·
Re: Bent Exhaust Intake Valves!?!?

Yeah I hear ya. Thanks for the help.
I guess there isn't anything I can really do.
I was just checking to see if they have a "crate" motor and Ford Racing does sell the SVT engine as a complete assembly. Of course it's $3,700 (MSRP) though!
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Maybe I could get an A-Plan discount thru my uncle??
There's one on eBay that's local to me and it's at $1,500. I guess I'd would probably try and buy a new one if I'm gonna have to get a new motor though.
I'm only scared about how hard or how much $$ installation would be!
 
#13 ·
Re: Bent Exhaust Intake Valves!?!?

That really sucks. That same thing happend to my Mustang, over reved it, bent a valve, broke the valve guide, and put a little dent in the piston. I also did that very same thing 2 days ago in my SVT, 4th to 2nd let the clutch out heard the front tires lock up. I'm lucky that so far everything is ok. I know my friend has also done this in his JRSC ZX3 a couple of times and it's still running good. I guess sometimes you get lucky and sometimes you don't.

Mike
2003 Silver EURO SVT #2272
2000 Silver Mustang GT Supercharged
 
#14 ·
Re: Bent Exhaust Intake Valves!?!?

If you never had it happen to you, you are not driving hard enough
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I grabed first from fourth under heavy breaking. Luckly I was fast on the clutch and I'd guess it only saw 8~9k. (its a good reason not to shift like a drag racer)
Heh... I drive plenty hard enough on occasion, but saying that I'm not driving hard enough because I've never missed a shift is a silly assumption. If I'm railing through the gears, I tend to be paying rather close attention to what I'm doing.
 
#15 ·
Re: Bent Exhaust Intake Valves!?!?

Yeah a similar thing happened to me yesterday. I was on a 2 lane highway and i decided id pass the prick actually going the speed limit (55) i tried to go for third missed, tried again and hit 1st. Thankfully no check engine light or anything.

Kurt
 
#16 ·
Re: Bent Exhaust Intake Valves!?!?

Well I just wanted to see what you guys all had to say about my little "mishap."
You are all correct though. I grabbed the shifter knob at a wrong funny angle and was trying to pull it back into 4th and I was at the angle for 2nd instead. Don't ask me how or why but I grabbed the shifter wrong, and thought I had an easy shift.
So yes, I know, very stupid.

So more than likely I'm screwed, huh??
I'm still waiting to see what the Ford Rep. says though b/c he still hasn't looked at it.
Is the only option to buy another SVT Focus motor??
Anyone ever price one out?? I'm guessing $3,000-5,000.
Any ideas would be more than helpful!

THANKS again.
I don't know why you would need to buy a whole engine. Most likely new valves, pistons, maybe a new head. You didn't throw a rod did you?
 
#17 ·
Re: Bent Exhaust Intake Valves!?!?

Yeah, I was going to say. Maybe you can have them tell you exactly what needs to be fixed, and just replace those things. Might be cheaper than a whole new motor. Maybe now is a good time to upgrade all the internals?
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#18 ·
Re: Bent Exhaust Intake Valves!?!?

I don't know why you would need to buy a whole engine. Most likely new valves, pistons, maybe a new head. You didn't throw a rod did you?
That's true.. the typical dealer WOULD try to stick him with a new engine.
 
#19 ·
Re: Bent Exhaust Intake Valves!?!?

the svt motor is a non-interfearence motor, you should not have bent a valve because of a missed shift or a over rev. Something else happened.

I have missed plenty a shifts in my 2.3l mustang and went way past the rev limiter, never bent a friggin valve because it is a non-interference motor. You would have had to push the valve almost all the way out @ on each pass of tdc on each piston to bend each of the exhaust valves, i went from 3rd to second gear when i first got the car and over-reved the crap outta the car when i did it, no problems since then....i'd like to know how that shop new you bent a valve, have they taken you motor apart if so tell them to keep it that way and you want them to show you each and every valve thats in that motor and have the car towed to a diffrent shop other then the ford dealership if there not. i'm callin bs on ford for this one. The valves won't even hit a table when you have the head off the car and you push on em.
 
#20 ·
Re: Bent Exhaust Intake Valves!?!?

Excellent point, dimm,

A clearance engine should not have any contact between the valves and the head, otherwise, when the timing belt goes out, the same thing would happen. As it is, if the timing belt goes out, the engine just shuts down.

In addition, there should be absolutely no need to mess around with the bottom end of the engine; the valves are in the head, which should be replaced exclusively. Honestly, it may be a do-it-yourself job; a head install is pretty simple (make sure those gears line up though!)

Andrew
 
#23 ·
Re: Bent Exhaust Intake Valves!?!?

Well I don't know what they did exactly at the Ford dealer. He said that the 8 Valves were bent and that it was "impossible" for that to happen.
I wanted to see it all apart for myself, but he said they had it back together and it was outside in the parking lot when he called me to tell me that. That sounded kinda fishy.
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And the service advisor said that the motor seized up and it needed a new one. So yeah it didn't seem like he knew everything he was talking about. You're probably right though, they just want me to buy a whole new engine. But I have no clue what needs to be replaced or what would need to be replaced.
Regardless, it won't be cheap!
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But someone mentioned upgrading the internals. But they really don't make anything to upgrade internally on the SVT, do they!?!?
 
#24 ·
Re: Bent Exhaust Intake Valves!?!?

Don't take anything lying down. Make them document AND show you everything, and make them give you a "reasonable" mechanism for what caused the damage based on your story. They HAVE to show you the damage especially if they want you to buy a new motor. Otherwise, I am sure everyone would get a new motor everytime they went to a dealer. Think of it like this: when you break your ankle, doesn't the doctor show you the xray?

Stand firm and fight it a tad. Also, how good is your insurance? You never know, some policies fix this if it is "driver's error" that causes mechanical damage.
 
#25 ·
Re: Bent Exhaust Intake Valves!?!?

Yeah that's what I was wondering. Could insurance possibly cover it???
I have full coverage thru Progressive. I thought that might be another possibility, but wasn't 100% sure if it was a feesible idea.

But yeah if this gets totally denied by Ford, then I want a thorough explanation of why and actually what is wrong with the engine.
 
#26 ·
Re: Bent Exhaust Intake Valves!?!?

Well I don't know what they did exactly at the Ford dealer. He said that the 8 Valves were bent and that it was "impossible" for that to happen.
I wanted to see it all apart for myself, but he said they had it back together and it was outside in the parking lot when he called me to tell me that. That sounded kinda fishy.
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And the service advisor said that the motor seized up and it needed a new one. So yeah it didn't seem like he knew everything he was talking about. You're probably right though, they just want me to buy a whole new engine. But I have no clue what needs to be replaced or what would need to be replaced.
Regardless, it won't be cheap!
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But someone mentioned upgrading the internals. But they really don't make anything to upgrade internally on the SVT, do they!?!?
Only pistons, rods, main caps, titanium valve springs, retainers, and Tom can get you staniless steel valves. So yeah, there are some options out there...
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