Stuck in regen??? - Ford F150 Diesel Forum
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post #1 of 120 (permalink) Old 03-03-2019, 09:45 PM Thread Starter
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Stuck in regen???

I had a new issue creep up today. Drove total of 700 miles round trip. When we started out on the last 350 miles I had 1300 miles of DEF left. When we got to our destination I have 430 miles left. I have used almost 2 full DEF tanks in 4880 miles. I also notice today that the truck was in a regen burn for 2 hours with 0% full on the filter. I keep a close eye on this to know when it starts to do a burn. It never got over 15% full and would go back to 0% for the most part. Fuel mileage was horrendous 16 mpg over 700 miles with no load. I was averaging 22mpg in the city. Seems to be some sort of reg issue I am now having. Anyone experienced this?

2nd question, what are the symptoms of the EGR flap bolts backing out other than the bolts ending up in a cylinder and granading the motor? Could this scenario be a by product? My truck goes in for a 2nd try on the recall tomorrow.

Many thanks in advance.
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post #2 of 120 (permalink) Old 03-03-2019, 10:10 PM
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@bone_scar - based on your % DPF full messages, poor fuel mileage, and DEF consumption, it sure sounds like you are stuck in a permanent regen.

I see from a previous post that you are FORScan-enabled. Is FORScan showing anything/throwing any codes?

I am now very interested in the outcome of your EGR recall...

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Last edited by jmperlik; 03-03-2019 at 10:13 PM.
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post #3 of 120 (permalink) Old 03-03-2019, 10:33 PM Thread Starter
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@jmperlik FORScan shows not errors under the DTC tab.
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post #4 of 120 (permalink) Old 03-03-2019, 10:46 PM
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@bone_scar - going to assume that this anomaly will be Priority #2 to discuss with your Service Advisor/Service Manager when you are in for your EGR recall tomorrow? Something is not right...

2018 Ford 150 PS Diesel Platinum FX4 in Ingot Silver w/BuiltRight Rear Seat Release, Gatorback F150 Splash Guards, Lloyd Custom F150 Luxe Carpet Mats & Titan 40 gal replacement fuel tank
FORScan mods: Auto Start/Stop Disabled, Bambi mode, Digital Temps Above Gauges, DPF Full %, OCR (Operator Commanded Regen) and Heated & Cooled seats on Home screen
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post #5 of 120 (permalink) Old 03-04-2019, 12:14 AM
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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.

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post #6 of 120 (permalink) Old 03-04-2019, 12:21 AM
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post #7 of 120 (permalink) Old 03-05-2019, 05:43 PM
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@bone_scar - how did your EGR recall go? Your dealer have any insights on your constant regen issue?

I did stop by my dealer and ran your symptoms by my Service Manager. He did tell me it is possible to "drop out of" a regen cycle when driving highway miles = was a surprise to me! He said if you are doing any "hard passing" where you may jump on the throttle for a few minutes to pass slower traffic, you are putting additional stress/load on the engine and it is possible to interrupt a regen for fear of an overheat/runaway condition in the DPF. He told me that you really want to keep things as consistent as possible for the 20-30 minute regen cycle to ensure full regen completion = pretty finicky!

No idea if this might be your problem and would find it hard to believe that this could be happening for an entire 350 mile leg of your trip, but thought I'd throw this out on the forum for comments. I am very interested in what your dealership's Service Department has to say on both your EGR recall & constant regen issue, and if they might be related.

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FORScan mods: Auto Start/Stop Disabled, Bambi mode, Digital Temps Above Gauges, DPF Full %, OCR (Operator Commanded Regen) and Heated & Cooled seats on Home screen
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post #8 of 120 (permalink) Old 03-08-2019, 12:03 AM Thread Starter
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Recall was done surprisingly quick. Took it in on Tuesday at 10am and picked it up on Wed at 10am. Replaced EGR valve and they reprogrammed the PCM, TCM and NOX modules. They said to keep an eye on it and see if the regen issue comes back with the latest calibration. So far the filter has not hit 100% since the repairs. I don't see any updated version release on the NOX or TCM listed on the paperwork but for the PCM they updated it to IDS version 111.03.The fuel mileage is night and day. Averaging 23mpg in town as opposed to the 16-17mpg before. The transmission is still not right when it hits 4th gear, so I am using sport mode a majority of the time. It seems to drag out 4th acting like the clutches are slipping. I am going to drive it another week and if it doesn't go away I will take it back in.

Overall I am loving the truck. I understand it being the first year its going to have some kinks to iron out. I am not so sure about this commingled 10 speed tranny though.
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post #9 of 120 (permalink) Old 03-08-2019, 12:05 AM
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I got the new calibration too, and yes it is a night and day diff in power for me. My MPG was fine. I hope this fixed it for you.

Tranny needs to learn, give it a few days of driving, if still not right in 4-5 days take it back. Mine shifts up and down butter smooth.
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post #10 of 120 (permalink) Old 03-08-2019, 12:10 AM
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I would not try to mask it and drive in sport, drive normal, if everything is OK it will smooth out, if not you need to break it now and get it fixed. Just my opinion.
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