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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: ‎FordPass
    b.) HTML link to FordPass app in Google App Store: FordPass - Apps on Google Play
  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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Discussion Starter #2
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 03/28/19)

Status as of 03/28/19:
 

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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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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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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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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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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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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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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.
It was only disassembled far enough to replace the valve. They bore scoped the intake looking for the missing screw and were unable to find it. Checked compression and are calling it good. Based on how loud it was knocking when I brought it in, I would bet that screw has been pounded into a piston or head.


Does anyone know if it is possible to bore scope the cylinders on these engines?
 

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Has anyone had any luck with Ford,. We can't get anyone to answer or call back. We have a customer care representative manager but she is like tracking down a unicorn.
 

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I have talked to customer service two times. Very nice young ladies I am guessing are in the Phillipines. About 30 minutes each call and I knew less after each call.
 

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Has anyone had any luck with Ford,. We can't get anyone to answer or call back. We have a customer care representative manager but she is like tracking down a unicorn.
I call Ford Customer Service pretty much every day. I have received a call back within 24 hours each time. So far they have...


Refused to work with me on a "buy back" option, always stating that it does not qualify at this time.


Refused my request for a ownership lifetime motor warranty.


Refused my request for a 100k motor warrant.


Offered me a 75k powertrain warranty, which I declined.


(All of this was when I was under the assumption that they would be rebuilding or replacing my motor.)
 

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A quick update on my truck. I received a call yesterday that my truck was ready to go. The dealership had put roughly 50 miles on it and reported that it ran good and it was no longer knocking. While they were driving it, I did get a notification from my Ford app that said the check engine light came on. When asked, they told me the tech forgot to hook up a few vacuum lines. When I picked the truck up I told them the only way I would except the truck was if they added a note to the work order that stated an EGR screw was lost in the engine. They agreed and I took the truck. I put roughly 40 miles on it last night and I felt like it wasn't making full power, but its hard to tell, I might just be paranoid. And a couple times I heard some rattling / knocking noises at low rpms when under load. At this point I'm driving down the road with the radio off, window down with my ear out the window. I'm calling the dealership this morning and requesting the "compression check" information they supposedly did.
 

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Discussion Starter #16 (Edited)
@jevalek77 - just to be clear, you already have a 5yr/100K base warranty on your 3.0L PowerStroke Diesel engine:

I call Ford Customer Service pretty much every day. I have received a call back within 24 hours each time. So far they have...

Refused to work with me on a "buy back" option, always stating that it does not qualify at this time.

Refused my request for a ownership lifetime motor warranty.

Refused my request for a 100k motor warranty.

Offered me a 75k powertrain warranty, which I declined.

(All of this was when I was under the assumption that they would be rebuilding or replacing my motor.)
Please review the Powerstroke Warranty thread for a discussion on this specific topic.

You can also request a VIN-specific OASIS report for your vehicle from your dealership's Service Manager to confirm this fact.
 

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Hey there was posting on another site trying to find answers and was directed to this site .
I have a 2018 F150 power stroke purchased January 30, 2019 it was involved in this recall as well they gave me the truck and let me drive it for three weeks knowing that the recall had to be done once they found out I was taking it on a long trip 5600 km round trip to Florida and back they said we must do the recall before you leave .
The truck ran fine all the way down and back but went through 15 gallons of Def towing a total load of approximately 6000 pounds I found that excessive and when I got back asked the dealer to check it they booked an appointment 4 days later
The day before the appointment I caught a check engine light that EGR is malfunctioning and diesel particulate filter was full the next day they checked it and said there’s nothing wrong and reset all coach didn’t make it 10 minutes and light came on again to days later engine started knocking it’s now waiting to be diagnosed.
I’m going to check this morning at the dealership and look at the old EGR if it’s still there and see if a screw is missing.
I do have a video of the knocking but I’m not very good with computers and don’t know how to download it if anyone wants to hear it you can PM me with your email address and I will send it to you
 

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So checked the old egr and both screws are still there so not sure what happened to my truck now. Will wait to hear what mechanic says tomorrow
 

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Mine has been parked at dealership since March 20. Ford Customer Service called and will be inspecting it at end of April or beginning of May. They again offered a loaner but I am still using my old 2013 F150.
 

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I’d seriously think about getting a lawyer to represent your interest.

That is way too long for Florida’s lemon law I would think.

I’m from over by Jacksonville and have a really good dealer, free oil changes for life and DEF plus lifetime warranty on engine and drivetrain. Palm Coast Ford.

Good luck,
KR2018
 
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