START HERE: Any owners affected by FSA 18E02 (EGR By-pass valve replacement) - Ford F150 Diesel Forum
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post #1 of 104 (permalink) Old 03-28-2019, 12:55 PM Thread Starter
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START HERE: Any owners affected by FSA 18E02 (EGR By-pass valve replacement)

This "sticky" thread is an attempt to:
  • Summarize a ton of information contained in the very large FSA 18E02 "master" thread: FSA 18E02 - EGR By-pass valve replacement
    ____=> Any Post #s referenced below in this thread refer to posts in this very large FSA 18E02 "master" thread
  • Provide a spot for owners negatively affected by FSA 18E02 to report their status
    ____=> Owners negatively affected by this FSA, please post to this thread
    ____=> Owners positively affected by this FSA, please continue to use the FSA 18E02 "master" thread above for commentary/feedback/opinion
  • Provide a spot for the FSA 18E02 spreadsheet I rolled up that summarizes all of our "Wounded Brethren" negatively affected by this FSA
  • Recognize all of those forum members who have contributed to the most popular/active thread on this forum

Please read this entire post before taking any action to avoid asking questions that may have already been asked & answered previously

What we (as fellow owners) know about FSA 18E02 (as of 03/28/19)
  1. EGR By-pass valve recall affects vehicle build dates from 09/13/17 thru 10/09/18 built w/3.0L V6 PowerStroke Diesel engines (from Post #31 by @RBaker dated 02/01/19)
  2. Specific issue is with one or both screws holding butterfly flap in EGR By-pass valve backing-out because they were not secured properly during manufacturing
    ____a.) Pics of what they screws look like/where they are located (See pics in Post #71 by @kdjasper dated 02/14/19)
    ____b.) New EGR By-Pass valve is same as original but both screws have been spot-welded to shaft (See pics in Post #245 by @Hawkwatcher1 dated 03/26/19)
  3. There is a currently a "Stop Sale" order on all F150 PS Diesels in-transit or in-stock that are affected by this FSA (Discussed in Post #15 by @jmperlik dated 01/31/19)
    ____a.) FSA 18E02 must be performed before owner can take delivery of vehicle from dealer
    ____b.) Request an VIN-specific OASIS report if you are purchasing a new or used 2018 Ford F150 PS Diesel
  4. Scans of official Ford documentation for FSA 18E02:
    ____a.) Ford US version => See Post #122 by @wreeedsvt dated 02/26/19
    ____b.) Ford Canada version => See Post #225 by @RBaker dated 03/22/19
  5. FSA 18E02 is documented to take 3.5 "shop/book" hours to repair, but:
    ____a.) Many owners are reporting much longer repair times (multi-day out-of-service repair)
    ____b.) Some owners have found improper re-installation of brackets/hoses/wiring harnesses back to their original state
    ____c.) Some owners have reported missing brackets and bolts
  6. FSA 18E02 is a "no loaner car" FSA but some dealers are making exceptions
  7. Ford 3.0L V6 "Lion" PowerStroke Diesel engines are only manufactured/assembled in Europe at the Ford plant in Dagenham, UK
  8. Ford 3.0L V6 "Lion" PowerStroke Diesel engines are only available in the following model/trim levels: XL & XLT (Fleet orders only), Lariat, King Ranch, & Platinum
  9. Ford F150 PS Diesels represent < 5% of all F150s coming off the assembly lines in one of two (2) US plants: Dearborn, MI and Kansas City, MO

Overview from EGR By-pass valve replacement Ford documentation (From Page 1 of 6 of Attachment III in Post #122 by @wreedsvt dated 02/26/19)
In some of the affected vehicles, it may be possible for one or both of the screws retaining the exhaust gas recirculation (EGR) by=pass valve flap inside the EGR cooler module to back out. This may result in loss of EGR cooling control, an illuminated Malfunction Indicator with DTC P2457 and the potential for reduced engine power. If a loose screw is ingested into the engine and vehicle operation continues, it is possible for engine noise to develop and the cylinder head and piston may become damaged. Before delivering any new in-stock vehicles involved in this recall, dealers are to replace the EGR by-pass valve.

Progression of symptoms
  1. First symptom could be an EGR cooler CEL (DTC P2457) which indicates generic error that the EGR Cooler unit is not functioning properly
    ____=> You may have already lost one or both screws in the EGR By-pass valve by this time
  2. If you get either of the following CELs, then you may be on your way to engine bucking & eventual engine failure:
    ____a.) P259E (TURBO BOOST PRESSURE LOW)
    ____b.) P042E (EGR CONTROL STUCK OPEN)

How to Determine if FSA 18E02 has been performed on your vehicle/VIN
  1. Install the FordPass app on your smart phone and check "Vehicle Details" section for any alerts:
    ____a.) HMTL link to FordPass app in Apple App store: https://itunes.apple.com/us/app/ford...s/id1095418609
    ____b.) HTML link to FordPass app in Google App Store: https://play.google.com/store/apps/d....ford.fordpass
  2. Ask your dealership's Service Manager for a full OASIS report on your VIN:
    ____a.) If they performed the FSA, it will be listed as completed
    ____b.) If the FSA hasn't been performed, the FSA will be listed as OPEN on the OASIS report for your VIN

What to do during your FSA 18E02 recall RO (Repair Order) while at your dealer
  1. Ask to see the old EGR By-pass valve to ensure both screws are intact (maybe take a digital pic for your records)
  2. Ask for your RO to be updated to reflect #1
  3. Inspect your vehicle post-FSA to ensure all wiring harness and hard lines are correctly re-assembled (See pics in Post #103 by @RBaker dated 02/22/19)
  4. If you are missing one or both screws, please continue reading to determine your fate

What are your possible actions/outcomes?
  1. Rebuilt Engine: Expect Ford to attempt a "short block" engine rebuild as their first offer
    ____a.) Expect to be out-of-service for more than 6 weeks
    ____b.) Expect the dealership to stick you in a loaner vehicle during your down-time, but don't expect a F150 (could car or SUV) or a F150 of equal trim level (could be F150 XL)
    ____c.) View the carnage of what this looks like in disassembly photos (See photos in Post #242 by @[email protected] dated 03/26/19)
  2. New "crate" Engine: Challenge your dealer on Ford's new Low-Time-In-Service Assembly Replacement Policy (Discussed in Post #154 by @jmperlik dated 03/12/19)
    ____a.) Effective with Repair Orders (ROs) opened on or after 03/01/19
    ____b.) Vehicles within 12 months/12k miles from the warranty start date requiring an engine or transmission repair may be eligible for a replacement assembly
  3. New vehicle: Exercise your rights under your state's New Car Lemon Law (Discussed in Post #251 by @jmperlik dated 3/27/19)
    ____a.) Most states have incorporated the following criteria into their New Vehicle Lemon Laws:
    _________ i.) number of visits or
    _________ii.) number of "down" or "out-of-service" days
    _______within a mileage limit or within the first 12-18 months of taking delivery of your new vehicle.
    ____b.) Your state's New Vehicle Lemon Law may vary, so please check your state Attorney General's website for details.

Thanks to all forum members that have contributed to the FSA 18E02 "master" thread and this thread!
__=> It took 4+ hours to document/edit everything above with names, dates, post #s, and links to create the above summary
__=> I took some liberty when "boiling down"/condensing 250+ posts into this summary & provided links to reference posts
__=> I apologize in advance to anyone I didn't "mention" explicitly by name, but I do thank everyone (especially those impacted) for their contributions

Good Luck to anyone negatively impacted by this FSA
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post #2 of 104 (permalink) Old 03-28-2019, 12:59 PM Thread Starter
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FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 03/28/19)

Status as of 03/28/19:
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File Type: jpg FordF150DieselFSA18E02.jpg (255.4 KB, 36 views)

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 #3 of 104 (permalink) Old 03-28-2019, 05:47 PM
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Well here's an update on my recall. After waiting for parts for the last 5 days finally they started on my truck today. NOT GOOD NEWS... One screw as I suspected was gone! The mechanic confirmed it was knocking when he pulled it in the shop. I'll try to attached some pictures. What's strange is it does appear the screws in my valve were welded on the heads? Now I guess I'm waiting on Fords instructions. And for the record I will be demanding a brand new truck.
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post #4 of 104 (permalink) Old 03-28-2019, 05:49 PM
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Attached are the pictures of my valve.
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File Type: jpg IMG_8083.jpg (61.7 KB, 57 views)
File Type: jpg IMG_8084.jpg (74.6 KB, 53 views)
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post #5 of 104 (permalink) Old 03-28-2019, 08:51 PM
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Quote:
Originally Posted by jevalek77 View Post
Well here's an update on my recall. After waiting for parts for the last 5 days finally they started on my truck today. NOT GOOD NEWS... One screw as I suspected was gone! The mechanic confirmed it was knocking when he pulled it in the shop. I'll try to attached some pictures. What's strange is it does appear the screws in my valve were welded on the heads? Now I guess I'm waiting on Fords instructions. And for the record I will be demanding a brand new truck.
Good demand it! Everyones truck who ate a screw at less than 10000 miles should be entitled to one. Let us know how it goes.

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post #6 of 104 (permalink) Old 03-29-2019, 03:50 PM
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Excellent thread. I am still waiting but I noticed on Ford Pass they moved it 14 miles last week. I didn't see any codes thrown, so I don't know if it is coming together or not. I am guessing they had diagnostic tools plugged in so maybe it doesn't send a code it they are working on it? I don't know. I have exceeded both the 3 visits and the 15 days required in Florida so I am not going to comment about this again online until it seems to be resolved. Looking forward to hearing good reports on the others as well as on mine.
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post #7 of 104 (permalink) Old 04-01-2019, 04:36 PM
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Update on my disaster... I received a call back today from the Ford customer claims in regards to my buy back request. It was denied at this time, which didn't surprise me any. She said their technical service would be contacting the dealership with instructions for repairing my truck. This is where things when from bad to worse! I called the service manager shortly after for an update. He was told by Ford to install the new valve and check compression, if compression checks out good and no codes are thrown the recall is considered successfully complete??????? He also said they will assume the screw made it through the exhaust valves???? Keep in mid the engine was knocking something terrible when I brought it in, the mechanic that pulled it in the shop also confirmed it was knocking. The service manager said it sounded good today after they installed the new valve. They plan to drive the truck for the next few days to observe any abnormal behaviors before retuning it to me. WOW, I can not even believe they would release the truck without knowing where the missing screw was. Where do I go from here... Ask for a lifetime motor warranty?
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post #8 of 104 (permalink) Old 04-01-2019, 06:24 PM
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Originally Posted by jevalek77 View Post
Update on my disaster... I received a call back today from the Ford customer claims in regards to my buy back request. It was denied at this time, which didn't surprise me any. She said their technical service would be contacting the dealership with instructions for repairing my truck. This is where things when from bad to worse! I called the service manager shortly after for an update. He was told by Ford to install the new valve and check compression, if compression checks out good and no codes are thrown the recall is considered successfully complete??????? He also said they will assume the screw made it through the exhaust valves???? Keep in mid the engine was knocking something terrible when I brought it in, the mechanic that pulled it in the shop also confirmed it was knocking. The service manager said it sounded good today after they installed the new valve. They plan to drive the truck for the next few days to observe any abnormal behaviors before retuning it to me. WOW, I can not even believe they would release the truck without knowing where the missing screw was. Where do I go from here... Ask for a lifetime motor warranty?
I would find a experienced highly rated lemon law lawyer in your area and get his input.

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post #9 of 104 (permalink) Old 04-01-2019, 08:34 PM
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I would also pull an oil sample to be analyzed by your lab.
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post #10 of 104 (permalink) Old 04-02-2019, 01:11 AM
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Originally Posted by jevalek77 View Post
Update on my disaster... I received a call back today from the Ford customer claims in regards to my buy back request. It was denied at this time, which didn't surprise me any. She said their technical service would be contacting the dealership with instructions for repairing my truck. This is where things when from bad to worse! I called the service manager shortly after for an update. He was told by Ford to install the new valve and check compression, if compression checks out good and no codes are thrown the recall is considered successfully complete??????? He also said they will assume the screw made it through the exhaust valves???? Keep in mid the engine was knocking something terrible when I brought it in, the mechanic that pulled it in the shop also confirmed it was knocking. The service manager said it sounded good today after they installed the new valve. They plan to drive the truck for the next few days to observe any abnormal behaviors before retuning it to me. WOW, I can not even believe they would release the truck without knowing where the missing screw was. Where do I go from here... Ask for a lifetime motor warranty?
How far is your truck torn apart? Is the cab off like the other members? If they were able to repair the valve with minimal disassembly of the rest of the truck, I would be more inclined to accept the repair after a complete and thorough inspection. If they torn the entire cab off and the motor is completely out of the truck, I am sorry, but there is no way the truck is getting put back together like it was intended leaving the factory line. That is where I would draw the line and not be too happy about the situation.

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