tcobb

My warranty is a Ford Warranty and my Fusion has 117,000 miles. It covers my car fir 24,000 or 2 years which ever comes earlier. It does not cover the part number 50232 which is the catalytic converter, exhaust manifold and heat exchanger. Ford manufactured these three part’s together as one part (all three are welded together). So unfortunately, even though it is only my heat exchanger that has a crack and is leaking coolant onto the exhaust header and cat; Ford will not cover the heat exchanger as they have designed all three parts as one, to reduce their costs. So I do now need to pay for the full cost to replace a completely and operationally good Exhaust Manifold and Catalytic Converter to replace my Heat Exchanger ( two 1/2 diameter 1 foot long pipes that transport coolant back and forth between the engine and the heater core. IMHO poor manufacturing design leading to my out of pocket cost of $2150 because Ford accepts no responsibility, saying because the part number includes the cat (which is working perfectly and I just had the state emissions testing facility pass my car) then the need to replace the Heat exchanger also necessitates the replacement of the two completely good components being the exhaust manifold & cat. Thank you for your responses. Unfortunately my appeal to Ford corporate was rejected.

Ford just diagnosed the rapid loss of Coolant as being due to the Heat Exchanger being cracked and leaking onto the Exhaust Manifold. Estimated cost to replace Heat Exchanger is $2165, because the Heat Exchanger is welded to the Exhaust Manifold which is welded to the Catalytic Converter. Both exhaust manifold & catalytic converter are fine, but they say because this model has a “Catalytic Converter with Integrated Exhaust Manifold” that my “Total Fird Warranty” does not cover this repair because the warranty excludes the catalytic converter; but my warranty also states it does cover the “Exhaust Manifold”. I believe the ford warranty should cover the cost of this repair because it is the Heat Exchanger that is cracked and the heat exchanger is part of the exhaust manifold since it is integrated into the exhaust manifold and catalytic converter. Has anyone had this problem & do you have any thoughts on how I should approach the ford warranty claims adjuster???? Thanks for your help because I don’t believe I should be required to pay for a catalytic converter and exhaust manifold just to repair a cracked heat exchanger???

Ford just diagnosed the rapid loss of Coolant as being due to the Heat Exchanger being cracked and leaking onto the Exhaust Manifold. Estimated cost to replace Heat Exchanger is $2165, because the Heat Exchanger is welded to the Exhaust Manifold which is welded to the Catalytic Converter. Both exhaust manifold & catalytic converter are fine, but they say because this model has a “Catalytic Converter with Integrated Exhaust Manifold” that my “Total Ford Warranty” does not cover this repair because the warranty excludes the catalytic converter; but my warranty also states it does cover the “Exhaust Manifold”. I believe the ford warranty should cover the cost of this repair because it is the Heat Exchanger that is cracked and the heat exchanger is part of the exhaust manifold since it is integrated into the exhaust manifold and catalytic converter. Has anyone had this problem & do you have any thoughts on how I should approach the ford warranty claims adjuster???? Thanks for your help because I don’t believe I should be required to pay for a catalytic converter and exhaust manifold just to repair a cracked heat exchanger???

I just joined the Forum today and purchased a 2019 Ford Fusion Hybrid TItanium in July 2022. Seemingly in great shape, but had a few vibrations, so I decided to replace the motor/transmission mounts. Underside rear mount was a bit hard to replace but completed it successfully yesterday. My brother and I were working on the car (reasonably competent weekend mechanics) and we googled and YouTubed the replacement of the Driver Side Upper Mount and could not find any instructions anywhere. We spent several hours taking the top engine shroud and brackets off, but could not figure out how to remove the FUSE BOX tray that sits just to the side of the Mount (need to remove it to get at one of the three to five bolts on the mount. Can anyone provide instructions on how to remove and replace this Driver Side Mount with pictures if possible (understand if no pictures) and if there are no instructions on how to remove the Mount; could anyone tell us how to get the FUSE BOX that is just to the right (in the photo, taken at from the front of the engine looking at driver side). Three pictures show a close up of the Fuse box with the Bolt and bracket from the Mount showing just to the upper left in picture (there is some fastener under the fuse box that we could not locate and would not let us pull the fuse box out, after we removed the two black cables with the black boxes on in the picture.....must be a trick to taking the fuse box out and we did not want to break the box or connections). The middle picture is from the front of the engine looking back towards driver side steering wheel, shows the location of the mount in the upper middle with black 1 inch bracket and bolt just peeking out (between the orange cable and red/positive battery cable that connects to the fuse box). Picture on far right is a close up of the black mount bracket and bolt on top of the mount.....I believe there are three bolts around the outside of the middle bolt, that need to be removed to get the mount out. MAIN PROBLEM STOPPING US, IS THE FUSE BOX REMOVAL, TO GET SOCKET/RATCHET TO THE RIGHT OF THE MIDDLE BOLT YOU SEE IN THE PICTURES, TO REMOVE THAT MOUNT BOLT. Thanks for any help from the forum members who may have replaced their mounts or knows how to remove the fuse box completely from the bay to get at the lower bolt for the mount, which the fuse box sits on top of.