In anticipation of a long drive, I took the Figo down to the Ford A.S.S to get the oil changed (6K done on old oil but full city commute) and a general check up.
They raised the car on the lift to drain out the old oil but noticed a lot of dried/moist oil stains around the sump seal where the sump is fixed onto the block. There was no residue oil near the drain plug so it was clear the oil was from the sump seal and not the drain plug. Also the leak must be minor as my basement does not have even a drop of oil below the car. The SA said this was higher than what was seen on other cars and decided to remove the sump, remove the old seal and put in a new one. Ford does not use a rubber gasket for the oil sump but uses a sealant paste. This paste is made in Japan by Mazda. The sealant tube costs a whooping Rs.8,400. Luckily one tube can be used for 10 cars so actual charge is around Rs.900. This was free for me as car is under warranty.
They removed the sump by opening all the bolts, cleaned it up and applied the paste. They put the sump back on and started assembling all the bolts. At this point they realised that there was one bolt which was only half in length!!!!
One stupid bolt broke and more than half is stuck in the threading of the engine block!!!!
Frantic scenes followed with the GM coming down to see and 5-6 SA's all around my car. Finally the decision was made to remove the sump again and clean out the bottom of the block. This showed the sheared off bolt inside one of the threads a good 4-5mm deep i.e. not even a mm outside. SA took a photo of the bolt and they sent it to Ford HO in Chennai. Ford Chennai said they will get back with further instructions.
Not having heard from HO in 2 hours, the SA requested me to leave as nothing much can be done. They would keep me informed once they got some news. They covered the crankcase with a plastic bag to ensure no dust goes in. They said they can't do anuthing on their own as the car is under warranty and any action requires Ford approval. I thought Metro Ford really handled this situation well and did not hesitate to escalate the matter to HO. It helped that I usually am with the car for every service and checkup. Went back home a bit off colour which had nothing to do with Holi.
Today morning got a call from SA saying they were told to remove the bolt using a special anti-clockwise drill bit and this was being done as we speak. Basically they would drill a hole of a smaller dia into the screw that was stuck in the head. They would then insert an anticlockwise screw into the hole and turn it. This would cause the sheared screw to unscrew and pop out. Once the screw was removed, the oil sump was put back along with new seal. The SA called requesting permission to go for a 10km long TD to ensure there was no oil leak. I approved of the same and was then informed after an hour that there was no leak whatsoever and everything was working fine. Since I was to go on a long drive, the air filter was cleaned, coolant topped up, windshield washer fluid topped up, Ac filter cleaned, gear calibrated, brakes cleaned and car washed.
I could only collect the car in the evening at 5pm after work and when I reached the SA showed me the broken bolt. The threading on the bolt was intact which was a relief as that meant the threading in the engine block would also be alright. The bolt just gave way in the middle.
I took it for a spin and found everything alright. The bill came upto Rs.1,969 which was only for oil and oil filter replacement and 5 litres diesel.
Overall I was very satisfied with the way Metro Ford handled the situation. The experience was not unpleasant something that was possible given the circumstances.
What remains a mystery is how this bolt actually broke? There are only 2 possibilities. One being the bolt itself was defective i.e. metallurgical issue in manufacture. Second being that the mechanic overtightened the bolt causing it to break. They did use a torque wrench but one will never know if it was set for the right torque meant for that bit as per service manual.
It goes to show that even a small minor oil change can end up leading to a lot of complication and a stressful experience. Luckily I can now go for that long drive which I almost had to cancel.
Alls well that ends well.