2019 Fusion Hybrid Titanium Coolant Leak???

[tcobb]

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??? 

[Waldo]

We need more details here on what warranty you are talking about.  Are you talking about the factory warranty, a Ford extended warranty or a 3rd party warranty?  How many miles are on your car?  Catalytic converters are covered by the factory emissions warranty, which is I think 8 years or 100,000 miles, so are you over 100,000 miles?

[billford]

Warranty items do not really go by names, they go by numbers.

The part you need is a 5G232

https://parts.ford.com/shop/en/us/hardware-and-fasteners/hardware-and-fasteners-71564-2/exhaust-manifold-and-catalyst-assy-6430705-1?pdp=y

The next step is to see if you warranty includes a 5G232. You can call a ford dealer and give them your vin and ask if this base number is covered under your warranty. 

Let us know the results.

[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.