[mascrappo]

Sounds like a bad tech... I don't find this ridiculous at all, i'm personally happy that ford has identified an issue, and are fixing it for me. This will be the first time that my truck goes into the shop since i bought it 2 years ago

Yes very bad tech. By ridiculous I should have made it more clear that yes I'm glad Ford found it, but what's up with faulty parts? Anything running in heat and or intake stream A: should have had screws staked in like anything with a butterfly plate so they don't back out (first valve issue) B: why are they using flimsy shaft to begin with knowing it's going to be cooked day in day out? I fear another recall coming next year for the same issue.

 

[schlotzj]

Well I dropped my truck off at the Ford dealership on Monday at 1200 hours. I called the dealership on Tuesday at 1200 hours and was told it was not done yet. I asked if there were any issues as the recall only calls for 3.5 hours to complete. The service advisor said there were no issues and basically the 3.5 hours is not practical. He said it would likely be done on Wednesday but called later that night to say they had to order a coolant pipe (JL3Z8555C) earlier in the morning which didn't arrive yet. He claimed the pipe bracket bolt is a one time use and the bracket is built into the pipe...I couldn't make sense of his explanation and I'm assuming he isn't explaining it correctly. He said it could be Thursday now until it is completed but as of 1200 hours today the part still has not come in. I had the service advisor send me pictures of the old/new bypass valve beside eachother but they came out blurry. I plan to drive 30 minutes to the dealership tomorrow morning to look at things myself as I'm concerned of the horror stories shared by others.

My brother had the cam phasers and timing chains replaced in his 2014 Ford F-150 3.5L at this dealership...they did a clean job and the only issue he had was a minor oil leak from the valve cover gasket which they fixed. I'm told the repair is being completed by the diesel technician as I requested at the time of scheduling, although, the service advisor mentioned the morning I dropped it off that he was a new diesel technician. So I'm hoping I didn't make a mistake by leaving it there and that there isn't more going on. They fortunately gave me a courtesy vehicle (2020 Ranger) to drive when I dropped it off.

I also just found out that my truck did have the 18E02 performed (ODO 21 miles) at the dealership I purchased it at prior to delivery...along with the heater cord (18S45) and carpet shielding (18S27). I did open a claim with Ford Customer Relations regarding an extended warranty or other possible actions...

 

[jmperlik]

Well I dropped my truck off at the Ford dealership on Monday at 1200 hours. I called the dealership on Tuesday at 1200 hours and was told it was not done yet. I asked if there were any issues as the recall only calls for 3.5 hours to complete. The service advisor said there were no issues and basically the 3.5 hours is not practical. He said it would likely be done on Wednesday but called later that night to say they had to order a coolant pipe (JL3Z8555C) earlier in the morning which didn't arrive yet. He claimed the pipe bracket bolt is a one time use and the bracket is built into the pipe...I couldn't make sense of his explanation and I'm assuming he isn't explaining it correctly. He said it could be Thursday now until it is completed but as of 1200 hours today the part still has not come in. I had the service advisor send me pictures of the old/new bypass valve beside each other but they came out blurry. I plan to drive 30 minutes to the dealership tomorrow morning to look at things myself as I'm concerned of the horror stories shared by others.

My brother had the cam phasers and timing chains replaced in his 2014 Ford F-150 3.5L at this dealership...they did a clean job and the only issue he had was a minor oil leak from the valve cover gasket which they fixed. I'm told the repair is being completed by the diesel technician as I requested at the time of scheduling, although, the service advisor mentioned the morning I dropped it off that he was a new diesel technician. So I'm hoping I didn't make a mistake by leaving it there and that there isn't more going on. They fortunately gave me a courtesy vehicle (2020 Ranger) to drive when I dropped it off.

I also just found out that my truck did have the 18E02 performed (ODO 21 miles) at the dealership I purchased it at prior to delivery...along with the heater cord (18S45) and carpet shielding (18S27). I did open a claim with Ford Customer Relations regarding an extended warranty or other possible actions...

Some observations/comments/recommendations: (for you and others waiting for parts)

• 12:00PM start guarantees you a multi-day RO unless the diesel tech has done one before
  • Ask for 8:00AM start to give the tech the afternoon as spill-over to work into
  • Today is Thursday and this started on Monday 12:00PM = 2.5 days in? Ouch!
  • 8:00AM start for this diesel tech would not have mattered!
• Based on timestamps on pics, your tech took the full 4.0 hours to get old parts out
  • My side-by-side pic was taken ~2 hours into the RO
• Coolant pipe (JL3Z8555C) is not listed in the parts list for this recall
  • See Post #37 from @taylormade in this thread for parts involved
  • Bolt (Part #-N808684-S101) is an example of a one-time use part (for steering column)
    • If coolant hose/bracket was one-time use, it would have been in parts list for recall
  • My guess is that new diesel tech broke Coolant pipe (JL3Z8555C) during dis/re-assembly
• Same issue with brightness I had in my pictures (old part looks like a black hole!)
  • Tried adjusting brightness in your pics but results are grainy due to low resolution pics
  • Anyone planning to take pictures, override/turn-on the flash on your phone!
• I would not accept the truck back until you do a full inspection of all:
  • Hoses/clamps
  • Wiring harnesses
  • Brackets holding any pipes/fuel lines/wiring harnesses
• If you don't know what to look for: (Click on underlined Post #s to jump to post w/pics)
  • @RBaker posted "before" pics in Post #103 in FSA 18E02 - EGR By-pass valve replacement
  • @Dunrollin mocked up one of @RBaker's pics in Post #108 in same thread with arrows
  • @Dunrollin provided a video in Post #130 in same thread showing loose brackets
  • @wreedsvt posted a full set of "after" pics in Post #139 in same thread
  • @Dunrollin posted more pics with arrows in Post #180 in same thread
• Owners who have yet to have 20E04 performed may want to pop the hood and:
  • Look around at driver's side of engine where work will be performed to get acclimated
  • Take some "before" pics if you don't know what things look like/what to look for
  • Read thru FSA 18E02 - EGR By-pass valve replacement thread for what "can" happen
• We, as owners, "should" not have to worry about these details, but
  • Alas here we are again...
  • For those in the queue, you have been forewarned/made aware...

Hope you see this before you go for your visit today and pick up your vehicle.

Good luck and please report back how you made out!

 

[Steve_A]

Hi, How did you guys get parts ordered for this Recall? I spoke to my Service Manager (NH) and he told me that the parts are not available? I have almost 40k on my Diesel and it is running great; just worried about a ticking time bomb. Thanks, Love this Forum!

 

[jmperlik]

Hi, How did you guys get parts ordered for this Recall? I spoke to my Service Manager (NH) and he told me that the parts are not available? I have almost 40k on my Diesel and it is running great; just worried about a ticking time bomb. Thanks, Love this Forum!

Early bird gets the worm?

Besides calling my dealer first thing on Monday of Thanksgiving week after seeing this recall in FordPass on the previous Friday night, I didn't do anything special:

• Owners not paying attention here or in Ford Pass will be notified by recall letter in Jan 2021
• Shaft failure is possible as @Tsul is currently waiting to find out => See Post #80 in this thread
• Besides ensuring that your dealer orders the parts, not much you can do beyond waiting for Ford to restock their supply chain
• I did warn owners to jump on this ASAP in an earlier post before the parts supply dries up

 

[Steve_A]

Thank Jmperlik; I called the day I found this out as well, and have talked to them three times since. they state that there are no parts available. I am having no issues, but not sure what I should look for. Thanks

 

[wreedsvt]

Hey All!!
First post. Wanted to help how I can for this issue. Just got truck back last night from dealer, I have a 2018. Here a snip from my invoice. View attachment 1970

What dealer did you use?

 

[taylormade]

planet ford in spring

 

[schlotzj]

Thank you @jmperlik for the detailed guidance...it is much appreciated and I did get to see your response before I left. I'm very OCD and have really been cautious (pain in the dealers a**) about this recall after hearing others experiences. I did take before photographs prior to dropping it off so I could refer back to them afterwards to ensure proper installation. So I got to the dealership before 0800 hours this morning just as the technician was literally backing it out for a test drive. I did take better photographs of the old EGR valve and fortunately the washer/screws were still accounted for...I did note a little bit of buildup between the two valve barrels after 18K miles. The technician stated the job was not easy but was completed besides checking the transmission fluid at my request (free of charge) which was later determined to be within spec. While the truck was there I paid ($110) to have the truck washed, clayed and waxed as I have limited free time...so I left until it was cleaned.

I returned to the dealership that evening and checked out the very clean truck thoroughly. I did not find anything out of place and wouldn't have otherwise known it was torn apart. The truck drove normally and as of now no issues...I will check the truck out more tomorrow. I am glad I took notice to the recall in the FordPass app early and that it is finally complete...hopefully they got it right this time!!

 

[jmperlik]

@schlotzj - I was just going to post a question asking if it was going to be a 5-day job for your truck!

Good to hear everything is back together and excellent job of photo-documenting both your old part and "after" pics!

Your old EGR By-Pass Valve definitely had more carbon build-up on it compared to mine (which was replaced in Feb 2019 under FSA 18E02)

Did you just put brand new tires on? Them there tires got some serious "meat on 'em"!

 

[schlotzj]

@schlotzj - I was just going to post a question asking if it was going to be a 5-day job for your truck!

Good to hear everything is back together and excellent job of photo-documenting both your old part and "after" pics!

Your old EGR By-Pass Valve definitely had more carbon build-up on it compared to mine (which was replaced in Feb 2019 under FSA 18E02)

Did you just put brand new tires on? Them there tires got some serious "meat on 'em"!

@jmperlik - The Apple iPhone camera quality is amazing lol!! Is there anything I could use or do to reduce the buildup in the future? Yea I put on new Goodyear Wrangler Duratracs at approximately 13K miles as I was looking for more of an aggressive look...they are great tires and would highly recommend them.

 

[Canadian F150 Diesel]

Our F159 Diesel is scheduled in the shop on the 22 Dec to have this recall completed at 40,000k no issues to date.

 

[Steve_A]

Early bird gets the worm?

Besides calling my dealer first thing on Monday of Thanksgiving week after seeing this recall in FordPass on the previous Friday night, I didn't do anything special:

• Owners not paying attention here or in Ford Pass will be notified by recall letter in Jan 2021
• Shaft failure is possible as @Tsul is currently waiting to find out => See Post #80 in this thread
• Besides ensuring that your dealer orders the parts, not much you can do beyond waiting for Ford to restock their supply chain
• I did warn owners to jump on this ASAP in an earlier post before the parts supply dries up

Thanks for your wisdom...squeeky wheel gets the grease. Parts are now ordered for my Truck. Thanks

 

[mascrappo]

I returned to the dealership that evening and checked out the very clean truck thoroughly. I did not find anything out of place and wouldn't have otherwise known it was torn apart. The truck drove normally and as of now no issues...I will check the truck out more tomorrow. I am glad I took notice to the recall in the FordPass app early and that it is finally complete...hopefully they got it right this time!!

That is a beautiful repair, like it never happened! I am so envious.

 

[Fraidenburg]

Called for my recall on the 8th and they already have the parts. Truck is going in Tuesday the 14th. Sounds like there is no shortage of parts at this time. 19,230 miles on the truck with no problems yet.

 

[agetech]

Got mine done today, in at 8am ready at 2pm. 26,

000 miles.

 

[Milehghcty]

Not sure what I'm looking at in your photos schlotzj ... hopefully mine will be finished tomorrow and the service tech can show me. Dealer ordered the parts on Dec 3, then scheduled me for Dec 9. Suppose to be a one day fix. Then got a call they need an extra day, then another day, and hopefully will be completed on Saturday. This was the first this dealer has completed and the tech indicated it was taking a lot of extra time. Tech indicated that the thrust washer was there. The extra time was because they had to order another "O" ring as they had a coolant leak when completed. The reason for the extra days delay. Must be one heck of an "O" ring as seems like they could just hit Ace Hardware for one of those. I'm worried, but hopefully their training on my F150 will insure it was done correctly (perhaps for the next one they have to do)!!

 

[mascrappo]

Not sure what I'm looking at in your photos schlotzj ... hopefully mine will be finished tomorrow and the service tech can show me. Dealer ordered the parts on Dec 3, then scheduled me for Dec 9. Suppose to be a one day fix. Then got a call they need an extra day, then another day, and hopefully will be completed on Saturday. This was the first this dealer has completed and the tech indicated it was taking a lot of extra time. Tech indicated that the thrust washer was there. The extra time was because they had to order another "O" ring as they had a coolant leak when completed. The reason for the extra days delay. Must be one heck of an "O" ring as seems like they could just hit Ace Hardware for one of those. I'm worried, but hopefully their training on my F150 will insure it was done correctly (perhaps for the next one they have to do)!!

Yes it is frustrating that all the Ford dealers are supposed to be trained to exacting Ford standards, as they like to say, but so hit and miss! My first repair sucked, meanwhile Scholtzj's looks just like it rolled off the assembly line! UGH!!!

 

[jmperlik]

Not sure what I'm looking at in your photos schlotzj ... hopefully mine will be finished tomorrow and the service tech can show me. Dealer ordered the parts on Dec 3, then scheduled me for Dec 9. Suppose to be a one day fix. Then got a call they need an extra day, then another day, and hopefully will be completed on Saturday. This was the first this dealer has completed and the tech indicated it was taking a lot of extra time. Tech indicated that the thrust washer was there. The extra time was because they had to order another "O" ring as they had a coolant leak when completed. The reason for the extra days delay. Must be one heck of an "O" ring as seems like they could just hit Ace Hardware for one of those. I'm worried, but hopefully their training on my F150 will insure it was done correctly (perhaps for the next one they have to do)!!

@Milehghcty - I'll agree that it is hard to tell what end is up vs down in any of the static pics:

• You should use those for reference if you think something isn't right
• Best explanation of what could be wrong/what to look for is the video @Dunrollin recorded:
  • @Dunrollin provided a video in Post #130 in 18E02 thread showing loose brackets
  • In @mascrappo's 18E02, the diesel tech was so far behind that he just threw out both brackets holding the fuel lines (firewall & under steering column) rather than spending more time to reinstall them

Both 18E02 and 20E04 recalls require disassembly of the driver's side of the engine to get to the EGR cooler assembly including:

• Air Box
• Bracket holding fuel lines to fire wall
• Plastic "Xmas tree" clips (as @Dunrollin calls them) holding wiring harnesses in place
• Steering column
• Bracket holding fuel lines under steering column
• More stuff I'm sure I have missed

Once you have all of that stuff out of the way, all of the parts in purple in the parts diagrams below need to be removed in order to pull the EGR Assembly:

• Input coolant hose to EGR Cooler (9Y438)
• Output coolant hose from EGR Cooler (9Y439)
• Exhaust pipe inbound into EGR By-Pass Valve (9D477)
• Intake pipe outbound from EGR By-Pass Valve (9F468)

Net of all of this is that there is a bunch of crap to dismantle & reassemble to perform 18E02/20E04:

• This is why every Ford diesel tech is complaining (even mine!)
• Reassembling all of the above under a 3.5 hour time constraint leads to corners being cut
• In most shops, the tech is only being paid for the 3.5 hour "book" time (not how long it takes)

Most likely your diesel tech cut/nicked the O-Ring/Seal (HR1 or 6N652) on either end of 9Y438 (Coolant Hose Assembly) that caused your coolant leak:

You can ask @taylormade why I have all of these diagrams and am familiar with the Part #s!

 

[Milehghcty]

Thanks for the diagram. That's great. When the tech finished today, he did show me where the EGR valve was located and pointed to many things he had to dismantle to get it changed. This made the pictures posted more clear once shown to me. The way he described the O ring sounds exactly like the HR1 your diagram shows. He did say the spacer washer was present and had not fallen in the motor. Put about 50 miles since the change and all seems to work good and don't see any leaks under the vehicle (yet).