I'll admit a few things here, because I don't want to mis-represent myself. 1) I'm not a tribologist 2) I'm not a lawyer 3)I am a statisitical qualtiy control engineer. My "opinions" are not worthy of being quoted in court, which is where you're likely headed, if you have the time/money/fortitude to fight it out. But, that does not make my comments or insight worthless either. You came to us for advice, and now you question the almost unified response you're getting.
Regarding the "add pack" issue: for one thing, that's already been brought up, your Fe is sky high; average of 8ppm/1k miles. That's way more than normal for a well performing HDEO in a diesel engine. Also, adding a gallon of Rotella skews the UOA in your favor late in the game. In all honesty, that seems like a bit of a cover-up at this point. Also, UOAs do NOT show anything above 5um in size; you could have much more junk in the oil than you are aware of even at this point. A particle count analysis might also shed some light onto this topic as well.
I've suggested this, but you've declined a direct specific answer. So, now I'll directly ask you, nutsbolts: Have you engaged the specific oil manufacturer in your quest, and if so what information/assistance have they offered or declined?
Ford has the right, at this point, to shove the burden of proof onto you and/or the lube maker. Can the lube maker shove the burden back upon Ford? - perhpas yes, perhaps not.
CJ-4 compliant oils have many tasks, as do all oils. But one thing they are very good at, by necessity, is controlling soot, due to the ever increasing use of EGR. Not only is this important from a DPF standpoint, but it also is important to the internals of the engine. If you used a non-CJ-4 oil, then Ford has some legitimate footing to at least argue their side. Again, if the lube maker can show strong data that their product is worthy in the mis-application you chose, you might be able to heave the burden back upon Ford. Or, the lube maker might just tell you that you made a wrong choice, and therefore lump the burden of proof onto you, as they step aside. The problem here is that you probably don't have hundreds (if not thousands) of hours to spend on testing your selected oil/engine combination, nor the hundreds of thousands of dollars it would take to run such tests.
At it's core, I suspect that the engine was at fault for leaking cooling into the lube system. But, I also understand that when you veered outside the specified realms of engineering specs, you gave Ford the ability to deny you claim at the front end. In the end, you might still win, but are you prepared for the huge time/money/emotional battle?
I can shed some very legitimate light on this type confrontation, because I once involved myself in a "lemon-law" action against Ford. I involved the Ford "action response team", the Indiana Atty General, the BBB, and a lawyer. And my vehicle was completely stock and I had followed all Ford's recommendations, and it was still a massive fight. I ended up trading the vehicle in, because the dealership had mercy on me, and I tired of the battle. I was paying a note on a car that I didn't even have the use of! And the "lemon-law" depreciation rate allowance is not at all favorable (or at least was not at the time, in 1990).
So, in regard to your situation, I still have to wonder why you won't share the specifics of your plight? What gives? Why the mystery oil? They are the missing piece in this puzzle. Your whole claim is that the use of your non-compliant lube and extended OCI did not cause the turbo failure. So, where's the support of the lube maker? Or, did you already try that, and they dumped you for non-compliant use of their product? Further, everyone here worth their salt knows that if you extend your OCIs, then it's very advisable to do UOAs along the way. Do you have proof of successive UOAs showing trending of coolant contamination? Do you have UOAs every 5k miles showing the ranges of wear metals? From what I've read, probably not. You only did a UOA after you developed a problem, using a non-compliant fluid in a non-recommended manner, and after you pumped in some recovery HDEO.
I find myself, as do most people following this thread, doubting your credibility. I apologize if that offends you, but it's my nature as an engineer and a cop to call out things that don't add up. Like I said in an earlier post, you're finding out the hard way that warranty coverage and compliance are not boundless; there are pratical limits to most everything in life.
You might still win this one, but only after a long, hard-fought up-hill battle ...