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START HERE: Any owners affected by FSA 18E02 (EGR By-pass valve replacement)

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#1 ·
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 (PSDs) 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 a VIN-specific OASIS report if you are purchasing a new or used 2018 Ford F150 PSD
  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 @codywroberts@gmail.com 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
 
#2 ·
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 03/28/19)

Status as of 03/28/19:
 

Attachments

#3 ·
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.
 
#5 ·
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.
 
#6 ·
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.
 
#7 ·
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?
 
#8 ·
I would find a experienced highly rated lemon law lawyer in your area and get his input.
 
#14 ·
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.)
 
#15 ·
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.
 
#17 ·
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
 
#20 · (Edited)
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
 
#27 ·
Got the news today Ford has agreed to a buy back or refund our truck. Honest question would everyone buy a 3.0 again or switch to gas?
Cody, I went to pick up my second 3.0 Platinum, and it had hard water spots in the Black Paint. So after having my new truck delivered with CEL on and codes, seeing red coolant dried all over the engine bay, I decided the water spots were a sign and instead got the 5.0 gasser.

I wont get the gas mileage, but I just couldn't handle worrying every time I heard a strange noise or Regen didn't happen or whatever. So we're into our V8 Platinum and very happy. I'm sure Ford will get this corrected, just like the 6.7 issues after switching from the 7.3, but for us, we just couldn't worry about it.
Like I said in my posts, the dealer was Great.
 
#22 · (Edited)
@codywroberts@gmail.com - Congrats? Thank you for posting back with Ford's resolution to your situation, as this should help other owners caught up in this same dilemma...

I think that the Ford's Legal Counsel has figured out that they're not going to be able to avoid the "out-of-service" days criteria of most states' Lemon Laws w/o lawsuits & folded their hand.

You ask a very tough question regarding coming back with another 3.0L PS Diesel! I think if you poll most owners they are happy with what they have seen so far short-term, but this FSA 18E02 and horror stories like yours have shaken my confidence. Glad to hear you will stick with Ford and I can fully understand in your angst in going diesel again after your bad experience. If you do decide to come back to the 3.0L PS Diesel, we'll all be here welcoming you back!

Thanks again for feeding back Ford's resolution to the other owners here on the forum = This is good news for all negatively affected owners
 
#23 ·
Good, you deserve it. I think I would stay with the 3.0 personally, all new engine introductions seem to go through growing pains. If we only didn’t need the EGR crap like Europe and most of the the rest of the world this would be a no issue.

The engine itself is tried and tested in Europe. It’s not the problem, just the ingestion of it’s own exhaust waste that fowls the oil and reduces MPG here in the USA.
 
#26 ·
I have had my truck back for almost a week and put about 300 miles on it. There has been no engine knocking from what I can tell. I just have a hard time believing that as bad as it was knocking when it went in that there wouldn't be some long term damage. I had asked the service manager several times what the compression readings were, as they told me it was tested. Since he could not get me the numbers I asked to have it re-checked. It went in yesterday and each cylinder was 375PSI, leaving the compression differential at 0%. The service manager also stated the specs were 350 - 400 PSI. Now I guess I'm supposed to just keep driving it until the missing screw shows up.
 
#28 ·
I am finally off the sick list as well. Picked up my 2018 Lariat from the dealer yesterday, just drove it a few miles but it looks good under the hood. They had it since Mar 20 and the report shows a bunch of small external parts including a wire assy? I am still researching that one, photo attached. AU2Z-14S411-LB. I am betting it goes to the DPF. Also new fuel lines. Also reset learned values for egr valve. Anyway, tomorrow is a long trip for it, so hoping all is well.
 

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#29 ·
@Dunrollin good luck on your long trip, hope everything goes smoothly for you. It seems your dealer may have taken the time to get everything back to perfectly good working order, so hopefully that will be the case for you.
 
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#30 · (Edited)
Update on truck
Dealer has gotten back to me said compression is low on two cylinders and turbo is not producing any boost Ford service tech have said replace the turbo first we need to start with that. turbo is back ordered minimum of 2 to 3 weeks my service manager is not confident that this is the only problem and neither am I.
I put a call-in to Ford Canada customer service and my case has now been upgraded to a district manager to oversee it no talk of a buyback yet but I’m really hoping that that’s the route they go up in Canada we don’t have the same type of lemon laws as the states so each case is looked at individually if the turbo takes three weeks to come in that would be a total of 42 days that I have not had use of my truck that I purchased January 29, 2019
If they do offer a buyback I will get another 3.0 power stroke just think I got a bad one
 
#31 · (Edited)
Update on truck
Dealer has gotten back to me said compression is low on two cylinders and turbo is not producing any boost Ford service tech have said replace the turbo first we need to start with that. turbo is back ordered minimum of 2 to 3 weeks my service manager is not confident that this is the only problem and neither am I.
I put a call-in to Ford Canada customer service and my case has now been upgraded to a district manager to oversee it no talk of a buyback yet but I’m really hoping that that’s the route they go.
If that does happen I will get another 3.0 power stroke just think I got a bad one
You did, I think these are great engines, just need to get thru EGR mess. Ive had multiple 3.5 and 5.0 crap out for no reason, so nothing is immune.

I believe another member got a buy back. I would pursue that. There is no reason you should spend 60k+, then for it to blow up and sit at a dealer for weeks, only for them to rip it apart at a dealer and try to repair. IMO you should get a new truck, take these back to Dearborn and figure out what went wrong.
 
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#34 ·
Posting from my phone, not sure how that will work. Stuck at a dealer halfway between Florida and West Virginia. Same bucking and same codes as well as reduced power. It is having a lot of trouble climbing hills on the interstate. MIL is on. I left Florida at 4 AM so this really old guy is starting to wear down.
 
#35 ·
@Dunrollin - sorry to hear you're back to square one with your truck again Doug...

I give you credit for deciding to take the F150 Diesel for your trip north, but once again Ford and your F150 Diesel have let you down. I don't even want to think about the bind you are in mid-trip, let alone the verbal lashing you are probably getting from the missus... I think this outage pushes you over the limit for the Florida Lemon Law to kick in, so I'd start asking Ford when they are going to replace your vehicle.

Good luck on getting yourself out of this mess -- please keep us posted (BTW your message from your phone posted fine on the forum)
 
#36 ·
Jmprlik, I'm not sure I would label Ford with such damning language. First year technical issues happen and many of us have realized that with many auto's. I swore we would never by a first year redesign when my wife was driving the then all new Honda Odyssey with power sliding doors. As she was driving onto Kirtland Air Force Base, the power door opened for no reason with our baby in a car seat next to it. Took it to the dealer three times for same problem and Honda knew they had issues, but trouble shooting was unnerving. Baby seat had to go I. The third row until finally 3-5 months and the real fix happened. Not even going to mention the Accord brake system that was way undersized for the 4000 lb. Odyssey.

Point is, Dunrollin, me, and others on here are going, or have gone through stuff that is a PITA, but Ford will make it right, albeit, like the Honda, may take way longer than we want.
Hang in there Dunrollin, you and the wife are ever in Destin, pleas look us up. Florida has a excellent lemon law enforcement program if all does not go well.
 
#37 ·
Thanks guys, all is good. They cleared the codes and reset the engine to full power. They also test drove it and detected the intermittent bucking but it didn't throw any more codes. I drove it on to WV.

Ford so far has been very good. I have a case #, she (Ford cust serv) offered a rental or hotel and also agreed I could proceed on after she chatted with the mechanic. P042E, P259E. He also did several pinpoint tests and recorded the voltages. That dealer was great, Classic Ford in Columbia SC.