[xDiesel]

Great to hear Ford was good to work with! That is my experience so far. Agree that this is going to take a while. I have a commitment from Ford yet the formal process starts with a replacement VIN #. With truck shortages, it’s going to be a while plus the replacement was ordered a few months ago with it no build date yet.

 

[xDiesel]

EGR failed a second time with a washer ingested in the engine.

First time post but thankful to reading this forum since I purchased the 2018 F150 3.0 Powerstroke in March of 2019. I’ll try and keep this short.

The first issue with the EGR was a trip to Montana from Detroit. Starting with 2000 mile on the truck, the EGR failure sign was a loss of power on the way out to MT. The truck needed to be floored to keep the speed up. I was pulling an 18ft enclosed trailer with a XP4 1000 RZR for an adventurous SxS trip with the family through MT, Idaho, and Wyoming which is ~6000lbs. After pulling over and refilling the truck it went away. On the way back, the same thing happened again. Flooring it was the only way to keep it going and had to pull over at a rest stop. Managed to make it home but the next day without pulling the trailer, I was on the side of the road in limp home mode. Limp home mode is the truck will only go to make RPM of ~1200 rpm. ERG screws backed out and flap wasn’t open/closing properly. After 3 times to the dealer and printing off this Diesel F150 forum post, I had to explain to them what the issue was. At the time it was a service bulletin. They replaced the EGR and turbo at roughly 7k miles on the truck. There were no error codes for loss of power. Only when it went into limp home mode where instrument cluster showed several warning icons and error codes.

Summer of 2020 – no A/C – national back order. Again another trip to MT but this time no A/C.

With the new EGR and now 36K miles October of 2021, the EGR fails again with washer ingested in the engine. I have towed the same trailer with SxS to West Virginia and upper Michigan. I’d say roughly 40% of the mileage is towing that trailer. The day after towing the trailer back from a SxS trip to mid Michigan, I was running kids to soccer and had the same issue of looses of power. Shut the truck down for an hour and drove home. Almost made it home before loss of power followed by a pinging from the motor. No error codes or IP warnings with pinging motor right away. It took a few startups where is went into limp home mode. The truck went to the dealer where they had it 2 months to replace the long block and 2.5 pages of parts including turbo and EGR with #2 cylinder misfiring and piston damage. The dealership performed recall 20E04 EGR bypass valve with cause 20E04B and replaced EGR valve assembly with 9U433-B. Its been in and out of the shop with multiple issues with intake manifold gasket leaking, diesel fuel covering the truck, exhaust leak, missing connection to crash avoidance sensor, oil leaking, etc. Overall 3 months to get it back with damage to bumper and still have an oil leak. I used to get 25-27 mpg and now only get 19 mpg.

I’m in the middle of Lemon Law settlement directly with Ford as they have accepted it with replacing the truck. Issue now is that there are truck shortages and no trucks to replace it. As much as I like the towing fuel economy 12 mpg vs 7 mpg on 3.5TT, having too many issues with complicated emissions doesn’t make it worth it.