They said oil pressure was low and timing was off. New engine is running great and getting close to 2 mpg better. Repair was about $7,500, all covered. I was very close to not getting extended warranty, have always been told it wasn't worth it. It cost me an extra $1,900 on the $23k vehicle.
I had brought it in a couple months prior to the same dealership because I was concerned about timing chain, when starting cold I could hear the slightest knocking/struggle(not sure how to describe it) for the initial 2-3 seconds then as I assume pressure built up it would return to normal. I only happened to hear it when using the remote start and was close to it, couldn't hear from inside. Their diagnostic was simply that I was not using the same oil filter as Ford, which as I understand it, has a flange that doesn't allow oil to drip/drain down when sitting.(I've seen others comment on this on the forum). The only reason timing chain was on my mind was I had convinced my colleague to get an expedition as he was looking for something to just haul the boat and friends to the lake on the weekends. He bought an 08 Expy with some 130,*** miles. Ended up having his timing chain break, which as I understand it, can be fairly catastrophic to an engine. It was only a couple weeks out from purchase(same Ford dealership I use) and no warranty. The dealership went 50/50 on the repair and remanufactured engine.