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Discussion Starter · #1 ·
So I unfortunately had to take my truck to the dealer to perform the EGR recall. Truck sat for two weeks because the tech had broken a "coolant line" and had to wait for a replacement to arrive. I get the truck back and about a week and a half later I notice coolant smells coming from the engine bay. I can see drops of coolant on the lower plastic shields but am having a hard time tracing the source.

I really do not want to take it back to Ford as I fear they will mess the truck up further. They gave it back to me with a load of things unfastened and even loose lug nuts on the drivers side. Also missing the lower lip which they claim they cannot find. Bunch of idiots.

So my question is, is there a write up article of video that details the EGR recall/swap? This way I can look and see in detail what lines could have been touched and what needs to come off to get a better look. Can't see anything top side that is leaking, but you can see small traces of coolant especially in the lower fan shroud plastic cover.

Thanks in advanced!
 

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So my question is, is there a write up article of video that details the EGR recall/swap?
I haven't found one yet, I remember one Ford tech put up one that lacked much detail. But moving on, @Dijit had the exact same symptoms along with no help from Ford due to no parts available. I think I remember others here with the same complaint. Take a look at these three photos. This pipe carries coolant from the egr cooler to the water jacket on the engine. At the top is a small o ring. That probably isn't the issue as a replacement o ring is easy to find.

At the bottom of the pipe is another o ring (not in the photo) and again it should be easy to replace. The big problem is the middle joint which features a rubber sleeve. In Dijit's case the tech had ripped the sleeve but reassembled it anyway, and of course it leaked.

I hope this helps a little. Sorry you are having these issues, none of us should go through this.

ETA In one of the photos you can see tool marks where this pipe was removed with force, that seems to be part of the problem.



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Discussion Starter · #3 ·
Thanks for the info. I'll keep doing some research to see if I can find anything obvious. If not, I'll be needing to pull the fan shroud and stuff out of the way to find the culprit leak.
 

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I am not sure you have to do the fan shroud, but you will remove the engine cover and the tire and wheel, then the inner fender liner. Also I think maybe the pan under the engine? If you do go after the above pipe it comes off OK if you remove the bolt on the bottom, which I think is a 10mm. Then the bolt on the top and it ought to pry out. It is interesting to me that Ford hs apparently assigned a total of 4 hours to replace the egr valve. It takes me that long just to remove all that stuff!
 

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So I unfortunately had to take my truck to the dealer to perform the EGR recall. Truck sat for two weeks because the tech had broken a "coolant line" and had to wait for a replacement to arrive. I get the truck back and about a week and a half later I notice coolant smells coming from the engine bay. I can see drops of coolant on the lower plastic shields but am having a hard time tracing the source.

I really do not want to take it back to Ford as I fear they will mess the truck up further. They gave it back to me with a load of things unfastened and even loose lug nuts on the drivers side. Also missing the lower lip which they claim they cannot find. Bunch of idiots.

So my question is, is there a write up article of video that details the EGR recall/swap? This way I can look and see in detail what lines could have been touched and what needs to come off to get a better look. Can't see anything top side that is leaking, but you can see small traces of coolant especially in the lower fan shroud plastic cover.

Thanks in advanced!
Somewhere on this forum, there is a "coffee book" on the 3L PS that might be helpful. Sounds like the typical sloppy rush job that Ford seems to be inclined when doing this recall. It might be that the mechanic showered the engine compartment with coolant and it's burning off and evaporating from various nooks and crannies. Look and see if the mechanic was negligent in returning wires, etc in the proper holding points, etc. In my case, they did not and it was obvious that they have gone over the reimbursed hours from Ford and quickly put everything back assuming that I would never look in the engine compartment and notice... Having said that if they did not put the coolant line(s) back and its is leaking I would recommend bring it to a dealer so that its documented in case something goes really wrong and you blow an engine block, etc. Good luck.
 

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@Chrispy, sounds exactly like what I had happen. The rubber piece that @Dunrollin showed you is the culprit. You sound like you’re very savy with a wrench. The answer is simple as to what you need to do. If you take it back in, your Ford mech will have to take out the EGR again. There’s no other way. It looks like they forced mine and the result is the image below.
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I honestly don’t know how it didn’t leak more than it did. It would sometimes leak a god awful amount and other times it would hold for days. Message me if you want more info. I fixed mine with help from friends. Mine started leaking in April of this year. Said it would be 4 weeks to get the part in. They finally called in Sept. Ridiculous.
 
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