Join Date: Apr 2018
Location: St. Paul, Minnesota
I agree that this is abnormal behavior.
I keep a very close watch on my regens, which seem to trigger with my type of driving about every 325 miles. I have about 5,2xx miles on mine now, and only 2-3 regens have I observed making it all the way to 100%--my truck seems to kick in regen quite often ~85% full. I try to watch my % Full and try to plan my driving so that I have a longer highway run when I am over 75% Full, then once I get into regen I keep driving ~20 miles until I get all the way burned out to 0%, then watch for it to go back to 5% on the way back up, then I generally don't watch it as closely for about the next 250 miles. To be honest, this regen management the way I have been doing it has me thinking about doing a delete and not having to hassle with it anymore.
So far I have only added 2.5 gallon jug of Motorcraft OEM DEF, and I still have about 5/8 full, so seems my truck is not a heavy drinker of DEF, but I imagine that will change once the ice melts and I start towing my boat around. One thing to know, DEF usage is continuous while driving, not just used during regen cycles. Your type of driving determines how much DEF is needed, with towing or driving loaded down causing greater fuel burn and thus more DEF usage. My DEF gauge mileage remaining has shown unexpected changes in the miles remaining, so now I just go by the gauge and not the mileage remaining.
I am only aware of one forum member that had lost screws in the engine from the EGR, but his truck was throwing a couple CEL's before he took it in for the recall.
I would definitely get your truck into the shop asap and avoid driving it other than to the shop if at all possible.
2018 Ford F-150 King Ranch FX4 3.0L Power Stroke 4x4, Long Bed & Trailer Tow Mirrors | Spray-in & Wheel Well Liners & BAKFlip CS/F1 & BAKFlip BakBox 2
ForScan Mods: DPF Full %, Bambi Mode, Show Temps Above Gauges, Operator Commanded Regen (OCR), more to do...
Traded In* ---> 2010 Ford F-150 King Ranch 5.4L Triton, LINE-X & BAKFlip CS/F1