[mascrappo]

Thanks for pics, yes engine installed first it seems then all the rest added. I could do the job myself, taking my time, but Ford has to do it so wish me well!

 

[Andy]

Mine is one of the "learning curve" recalls for the dealership. Dropped of 0745 on Friday 12/11 and I called around 1530 that day only to be told that the tech had "a ways to go". After voicing my displeasure, the service advisor did say that the 3.5 hours was not practicable and that the tech is being very through as this is the first they have done. I did take pics before I dropped it off and will examine with a fine tooth comb before I leave dealership- hopefully this afternoon. I do have a hard time believing Ford missed the book time by a 150% or so.... My guess is the majority of techs have rarely, if ever put hands on this engine.

 

[Dunrollin]

My guess is the majority of techs have rarely, if ever put hands on this engine.

I think you are spot on, which is why a technician like @Kval is so valuable to a dealership. I hate to say it but I haven't found a tech around here like that yet.

 

[jmperlik]

FYI - pics from Page 39 of 3.0L Ford F-150 Diesel Coffee Table Book that show how EGR By-pass valve (in green) sits in the middle of the EGR Cooler assembly and where the various hoses connect:

• Coolant enters the EGR cooler via Input coolant hose (9Y438) at port indicated by blue arrow
• Coolant exits the EGR cooler via Output coolant hose (9Y439) at port indicated by red arrow
• EGR By-Pass valve assembly is the part circled in green in lower picture
  • EGR By-Pass valve assembly is the part being replaced in 20E04 recall

 

[Laytunes]

Mine is one of the "learning curve" recalls for the dealership. Dropped of 0745 on Friday 12/11 and I called around 1530 that day only to be told that the tech had "a ways to go". After voicing my displeasure, the service advisor did say that the 3.5 hours was not practicable and that the tech is being very through as this is the first they have done. I did take pics before I dropped it off and will examine with a fine tooth comb before I leave dealership- hopefully this afternoon. I do have a hard time believing Ford missed the book time by a 150% or so.... My guess is the majority of techs have rarely, if ever put hands on this engine.

Being the first is not necessarily a bad thing. They will probably follow the procedure to a T. It's when techs have done the same thing 100 times where they start to cut corners and get complacent, as they know they can save 10 minutes if they just bend this, or force that, or skip a step. The tech is probably sitting there with the book open, doing everything as ford says. I wouldn't worry.

 

[dhuyck]

Dropped mine off today at 8am. Dealer rep provided a loaner and said it should be ready in the afternoon. That was before he found out one of his two diesel techs was going to be out due to his wife contracting COVID. This couple with them ordering the "wrong valve" causing them to do an emergency order on the proper part....which sounded like the service rep simply trying to pacify me and not that he knew what he was talking about....they really should put people on the phone who know what they are talking about. Anyway, my impression is that I will have the loaner for a bit - which is fine I will put miles on their vehicle for the holidays! This dealer did a good job on the first recall and I told them to take their time and do it right this go round as well. Glad I took pictures beforehand!

 

[Andy]

Picked it up yesterday late afternoon and all looked well. Service advisor said it was a royal pain to complete. Drive home and all was well until I went out into the garage later in the evening. Puddle of coolant on the floor. Crawled underneath to get an idea of where it may be coming from but can't really tell. Underside as well as side of engine covered in coolant, reservoir tank well under the MIN mark. It was at the MAX when I pick it up from dealer. Another pleasant call to the dealer this AM as soon as they open. Not all the trucks fault, just disappointed in the level of service/knowledge that seems to be the standard these days. That is not a knock on Ford techs, there are some phenomenal ones out there, I just struggle finding one!

 

[jmperlik]

@Andy - check your fluid level to see if it is drive-able but get it back to the dealer, since this was obviously caused by the 20E04 recall work...

Just went thru something similar with @taylormade where he asked me to contact him after he found coolant gushing out of the "bell" part of Hose Assembly 9Y438 roughly 10 days after his 20E04 recall was performed. I posted the parts diagrams for the EGR cooler assembly and picture of the hose in Post #99 of this thread for reference. While this part is called a "Hose Assembly" in the parts list, it is really a pipe (all metal) with a 90 degree elbow, that looks like it might swivel but it doesn't. Current working theory is that there is an internal seal under the "bell" part of the assembly that split when his diesel tech tried to swivel 9Y438 to move it out of the way. @taylormade is currently in a holding pattern waiting for a new 9Y438 Hose Assembly.

If you don't have a huge (like multiple quarts) puddle under your truck like @taylormade, then most likely issue is the HR1 seal on the EGR Cooler side of 9Y438 Hose Assembly was nicked or cut during dis-assembly or re-assembly process as @Milehghcty found in Post #97.

There are also paper gaskets on both sides of the EGR By-Pass valve (See Parts diagram in Post #99 or pictures in Post #104 above) that could potentially leak, but those are pretty flat surfaces that mate together, so I would find it hard to believe it would be leaking from any of the gaskets, but it is possible as coolant flows thru all three (3) parts of the EGR cooler assembly.

Good luck getting your truck back to your dealer and let us know how you make out.

 

[Andy]

@Andy - check your fluid level to see if it is drive-able but get it back to the dealer, since this was obviously caused by the 20E04 recall work...

Just went thru something similar with @taylormade where he asked me to contact him after he found coolant gushing out of the "bell" part of Hose Assembly 9Y438 roughly 10 days after his 20E04 recall was performed. I posted the parts diagrams for the EGR cooler assembly and picture of the hose in Post #99 of this thread for reference. While this part is called a "Hose Assembly" in the parts list, it is really a pipe (all metal) with a 90 degree elbow, that looks like it might swivel but it doesn't. Current working theory is that there is an internal seal under the "bell" part of the assembly that split when his diesel tech tried to swivel 9Y438 to move it out of the way. @taylormade is currently in a holding pattern waiting for a new 9Y438 Hose Assembly.

If you don't have a huge (like multiple quarts) puddle under your truck like @taylormade, then most likely issue is the HR1 seal on the EGR Cooler side of 9Y438 Hose Assembly was nicked or cut during dis-assembly or re-assembly process as @Milehghcty found in Post #97.

There are also paper gaskets on both sides of the EGR By-Pass valve (See Parts diagram in Post #99 or pictures in Post #104 above) that could potentially leak, but those are pretty flat surfaces that mate together, so I would find it hard to believe it would be leaking from any of the gaskets, but it is possible as coolant flows thru all three (3) parts of the EGR cooler assembly.

Good luck getting your truck back to your dealer and let us know how you make out.

Nope, not quarts just dripping... Just called them and I'm gonna sneak out of work for a few (shhh) and run it to the dealer. Betting it just the O ring. Fingers crossed!

 

[Tsul]

Well my bypass shaft was broken but all parts are accounted for. I am picking the truck up tomorrow and will have a long talk about this being documented. If you guys throw any check engine for egr cooler performance park the truck and get it looked at. I love this truck and engine and do a lot of trailering with my boat and livestock trailer and I just wonder if that has added to the stress on the bypass?

 

[jmperlik]

@Tsul - sorry to hear that you are the first victim of the actual recall description for 20E04 = broken shaft. Not sure if your towing and the By-Pass valve shaft are inter-related = need to ponder that...

Got a bunch of questions:

1. Can I ask where were the broken pieces found?
2. Was the flapper plate hung up in the By-Pass valve assembly?
3. Do you know if the thrust washer passed thru into an engine cylinder?
   Or did it stay on the shaft in the channel in the valve assembly?
4. What is Ford's position on your truck/engine?

I did hear one 18E02 horror story of the screw being ingested into one cylinder, passed out thru the exhaust valve, only to pass thru the EGR By-Pass valve again into a different cylinder, like a ping-pong ball eventually trashing 3 cylinders in all.

I have to believe that Ford found at least one EGR By-Pass valve fail this way as part of 18E02 recalls to initiate 20E04. Going to assume your EGR-related P2457/P245B codes were due to the fact that the flapper plate was dislodged/partially opened and not working as designed. I am hoping that the shaft failure has a better outcome than 18E02 (missing screws) as the flapper plate definitely can't go anywhere & causes P2457/P245B codes to be thrown quickly, and maybe the washer causes less damage than the screw(s) if ingested into an engine cylinder?

Please keep us informed of what transpires, as I am interested in how Ford handles what happened to you. especially since this is 2nd go-around for this same EGR By-Pass valve.

 

[thegert87]

Called my local dealer, 11/30 and they told me they were going to order the parts. I called today 12/7, and they are back ordered. No details on when they'd be in. Anyone else waiting for parts to arrive?

Mine was finished Monday, after 6 hours. Nothing wrong with old one, haven't noticed any installation issues.

 

[Andy]

After the return trip for coolant leak the tech pressure checked the system and absolutely no leaks. The explanation for what I was seeing was that it was residual that was spilled while preforming the recall. So I said skeptically, "ok" but when I first picked it up I checked the coolant and it was at the MAX mark. Now its well below MIN mark. He said the system likely burped due to air being introduced during reassembly and filling. To which I replied " I was told the truck was test driven twice and then checked over one final time. Wouldn't the burp of air happened then? And the low coolant level presented its self?" He looked puzzled and and finally said drive it for a while and watch coolant level. If it drops below MAX again bring it back. Finding competent service and support has been and continues to be a glaring issue that none of the manufacturer's or dealers seem interested in correcting.

 

[jmperlik]

After the return trip for coolant leak the tech pressure checked the system and absolutely no leaks. The explanation for what I was seeing was that it was residual that was spilled while preforming the recall. So I said skeptically, "ok" but when I first picked it up I checked the coolant and it was at the MAX mark. Now its well below MIN mark. He said the system likely burped due to air being introduced during reassembly and filling. To which I replied " I was told the truck was test driven twice and then checked over one final time. Wouldn't the burp of air happened then? And the low coolant level presented its self?" He looked puzzled and finally said drive it for a while and watch coolant level. If it drops below MAX again bring it back. Finding competent service and support has been and continues to be a glaring issue that none of the manufacturer's or dealers seem interested in correcting.

(Sigh...) I agree it sounds like you are getting excuses for shoddy work, as their explanation for why you went from MAX line to below MIN doesn't add up:

1. I just don't flat-out buy their excuse of residual coolant spilled while performing the recall
2. Either you have a leak (and will be presented with another puddle) or you don't have a leak:
   a.) They added coolant to the overflow jug
   b.) They didn't drive it long-enough to the point where the thermostat would open
   c.) They didn't purge any air out of the system
3. Sounds like they are making excuses because they don't want to tear things back apart to check

Keep an eye on things and please let us know how you make out...

 

[mascrappo]

Mine is in surgery today, praying it goes well as it the first for the "Senior Master" Ford mechanic...

 

[Laytunes]

Just picked mine up and had a couple of positive observations. First the tech took a picture showing the old valve with everything intact which was good. After driving it I instantly felt that the steering was different. it was stiffer, and it doesn't react to the road as much as it used to. I think the process involves removing the steering column, so I think when they did my EGR originally in 18, they may not have re-assembled it or adjusted it properly, and now they assembled it properly. It feels much like the steering in the other F-150's I've driven now which is good, as I always wondered about that.

Another thing that I noticed is that they topped up my orange coolant with yellow, as you can see a clear difference in the overflow bottle. Ford discontinued the Orange (HOAT) coolant to replace with yellow (POAT), and they are interchangeable.

On another note, my TCM died as well before I brought it back in (just happened to occur right before the egr parts arrived so got them both done at the same time). They installed a new TCM, and re-flashed it with the most up to date strategy, and the tranny feels much smoother now, I don't get the 3-4 shift bump now, or noticeable shifts slowing down. The calibration seems much more refined. So anyone showing strange shifts, maybe look into getting the programing updated.

All together she drives like a new truck and I'm very happy to get this done. all for $0.

 

[wreedsvt]

Mine was dropped off this morning also!

 

[dhuyck]

Just picked mine up from the dealer this evening after dropping it off Monday morning. They told me Monday that they did not have the right valve so had to emergency order one....not sure if that was the truth, but if it was that means parts are not an issue because it came in quickly. Same tech ended up doing both this recall and the 18E02 (at least according to the paperwork). Had them send a picture of the old valve to make sure it was still intact. Carbon shown is from about 20,000 miles of mixed city/rural with some light towing - 18E02 valve put on at around 7,000 miles, this recall completed at around 27,000. I can also confirm that the valve installed was JL3Z-9U433-B. Also took picture (as best I could) of the area after the new valve was installed.

 

[mascrappo]

They keeping mine overnight I was just told, major surgery, monitor the patient...lol

 

[GearsGrindn]

I just got my truck back after dropping it off last Friday. I made an appointment after noting the recall on the Fordpass app. They verified they had parts in before taking possession of the truck. I requested a loaner when the Service Adviser said it would take 3 business days and they provided an Ecosport. So far the truck seems to be running fine as it was before the work. I noticed a loose trim panel that i will have them reset as well.

2019 4x2 Lariat