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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
 
#38 · (Edited)
How many miles on your truck Dunrollin? Sometimes bucking is caused by fuel filters. I have always done maintenance way before required, but I have lots of friends who do not. I remember Duramaxes bucking/kicking/ shifting weird, and it was always the fuel filter. It wasn't getting the correct amount of fuel so it caused the computer to go crazy. Not saying that is the problem but everyone needs to be very mindful to change the fuel filters on these truck regularly as diesel is a dirty fuel.

Those codes are both EGR and Turbo inadequate boost. Changing fuel filters is a easy thing to rule out.
 
#39 ·
had a friend come over the other day in a 17 F250 6.7, diesel and smoke pouring out from the hood. 60k on it and fuel filter never changed. It apparently has a relief valve or got so plugged its started spewing out under the hood. Never went that long with mine so I have no idea.

Said it had been not performing well for 10k-20k miles or so.

IDIOT. He is my friend but *d@mn. Idiot. lol Changed both filters and truck runs perfect again.

I have always had good luck with changing the fuel filters on a diesel between 10k and 20k. Closer to 10k most times, easy insurance.
 
#40 · (Edited by Moderator)
Thanks for the advice! This is my first diesel, so from what you are saying I will look to have my fuel filters changed out every other oil change; i.e., every 15-16k on how my driving and truck are behaving so far at ~7,600 and thinking I am going to get my first oil change in about a week, but I still have 29% oil life remaining and in my old 2010 5.4 I usually changed when the computer had me at 20% oil life remaining.
 
#41 ·
I know this is off topic of the intent of this thread, but I need to follow up on my previous post. Here in MN the fuel stations are mandated to serve us biodiesel blend.

Owners Manual states this for those of us running biodiesel blends...
"Every 30000 mi (48,000 km), six months or 300 engine hours, Replace the engine-mounted and frame-mounted fuel filters."

I am going to keep a more watchful eye on my engine hours, and probably have the fuel filters replaced every 300 engine hours.
 
#42 ·
My truck began the bucking and throwing codes at 1,695 miles. The only other mileage since then is 60 they did for diagnosis and my trip from FL 650 miles.

I am a bit of a nutjob on filters, both fuel and oil. I did bleed the water seperaor under the truck, pure clean diesel. It is some gremlin up in all those little electrical things I bet.
 
#47 ·
Can you ask for a copy of bulletin and post it?
 
#48 ·
anyone use the lemon law to get a whole new truck yet?

my 2018 with 13k miles on it has been at the dealer for over 30 days already, which meets our state requirement for the lemon law. The problem started with the warning light on the dash that said something along the lines of " limited power may be available" and went into to a limp mode. Dealer originally told me that it was something to do with a turbo hose, then on day 30 of being at dealer he springs this whole recall thing on me...which I had not been aware of. He has since told me that it did suck a screw into the motor (doesn't sound good to me), I'm very apprehensive to take this truck back even with a completely new motor in it. Just don't trust the mechanics at the local dealer to do everything 100% right. Way too many wiring harnesses, hoses, etc. to be re-run and secured properly. If anyone has any input with the lemon law on this truck or any vehicle that they used the lemon in CT would be greatly appreciated.
 
#49 ·
Sprink, welcome and best of luck with your issues. This ordeal really removes the "joy of ownership" and frankly it has become the biggest single problem I have in my otherwise boring life. You do get the feeling no one will help you on this, each of us is on our own. My truck is parked in the drive here in WV and Ford Customer Service advised me to take it back in to the dealer in FL.

Read your owners manual on arbitration and check your state's laws. Most states require you to submit to binding arbitration as a first step and that is where I am now. By the way, you qualify to be included in the forum's spreadsheet of dead and dying trucks! So there is that
 
#50 · (Edited)
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 04/22/19)

Current status as of 04/22/19:
- Highlighted cases with missing screws in red
- Highlighted cases with intact screws in green
 

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#51 ·
After waiting close to 4 weeks for a parts to come in the dealer finally received all parts and replaced turbo. It took over two days to complete the job got the call yesterday that even to their surprise everything seems to be working normal. No more knocking,compression is equal in all cylinders and driveability is good they put on over 50 km yesterday and just wanted to do a coldstart this morning to make sure everything was still OK and I get truck back this afternoon fingers crossed that this is all that is wrong.
 
#52 ·
Update
My selling dealer drove the 2hr drive to the dealer that replaced the turbo to pick up truck yesterday I picked up truck last night made it home everything ran great.
Then this morning on the 15 min ride to work check engine light on again.
I’m at wits end with this truck back to the dealership I go
I have owned every single Ford diesel since the 6.9 L this is by far the worst experience I have ever had I just want out of this nightmare
I still believe that I have a lemon and would probably get the exact same truck if Ford would just take this one back
 
#53 ·
Do you have a code reader or Forscan to pull the code?
 
#54 ·
Dealer pulled code P2457 egr cooler below threshold
This is the exact same code I was getting before they replaced the turbo I asked the tech to see if he could pull up all the codes since day one I have them on my phone now it’s over four pages long
I called Ford customer service Canada again my case is being escalated to the next level of Manager
This is now at the third level whatever that means LOL
 
#56 ·
I have the same code, p2457. Popped up last week. Then the turbo began over boosting, code p0234 while I was waiting for my appointment. Turbo was quite a bit louder then normal and would have a fluttering sound when letting off the gas. Fluttering almost sounded like a waste gate but I know this truck does not have one. Still waiting for the dealer to call. 3 days in the shop.
 
#58 ·
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 05/05/19)

Current status as of 05/05/19:
 

Attachments

#60 ·
Just an update of my problem. Started with a p2457 code (egr cooler efficiency). Then had p0234 pop up for over boost a week later. Went back 2 times to pick up truck because they thought it was fixed. Drove out of the lot and accelerated quickly, boost gauge pins all the way and cel comes on for p0234. Immediately return each time. Now, Ford thinks it needs a new egr. In goes my second egr when parts get in. Not sure it will fix it but it was the first problem. I am just not sure how it is causing overboost.
 
#62 ·
@Dunrollin - good to hear that Ford folded-their-hand and decided to offer a buyback for your truck, as I think they are caught-with-their-pants-down WRT to having a fully stocked supply chain to actually try to repair any of these new 3.0L PowerStrokes out-in-the-field. For those negatively affected owners who have posted, Ford seems to be taking 3-4 weeks just to get the parts to replace the first time, so they are blowing the limit on the out-of-service days for most state Lemon Laws in just that first RO.

What we never figured out with your truck was what really went wrong... With such low mileage, I would be surprised that you lost a screw, but I guess anything is possible. I think you stated in another post that your dealer never specifically mentioned if there were any missing screws in your original EGR By-pass valve. What is your opinion? Do you think one or both got sucked into the engine? If not, what do you think was causing all of your engine issues?

Bigger question I guess is: Do you have the heart to go thru this again with another F150 3.0L Diesel?

I wish you the best of luck Doug, as I have been amazed by your patience with all of this, so I am glad Ford is standing by their product and doing the right thing in your case.

I will update the spreadsheet with your outcome tomorrow.
 
#63 ·
Thanks! First, we love the truck. Still less than 3,000 miles but last weekend we decided to take a trip in it and ended way back in the mountains. For about 1 hour we lost cell contact and that was when it began bucking. My wife was a little shaken LOL. Anyway she still refuses to drive it.

It only has one issue but no one has yet figured out what it is. My best guess is the egr recall mechanic screwed something up because that is when it all started. I doubt I will ever know.

Probably late fall or next winter we will replace it and it will be a diesel but not positive exactly which model. Meanwhile my 2013 F150 5.0 is still running like a champion so no hurry. I love the trucks, not the dealers but Ford has been good to keep trying to fix it.
 
#66 ·
Those EGR screws are pretty small. Does anyone think that a lost EGR screw in the engine could exit the engine during an oil change and no longer pose a risk to the engine? It's just a thought I had on this recently.

Perhaps those that have lost a screw or two have already dropped out the screw during an oil change. Or, for those that have this situation, maybe have the used oil strained to see if the screw(s) came out and if found in the used oil it would provide piece of mind that there are no longer loose screw(s) in the engine.

It may even be worth pouring in a couple gallons of oil with the oil drain plug out to try to flush out the screw(s) from the engine?

Just trying to provide some comfort or possible hope to those on @jmperlik wounded brethren spreadsheet.
 
#67 ·
Just trying to provide some comfort or possible hope to those on wounded brethren spreadsheet.
Sorry, but I'm confused. How would a screw get into the oil? The valve is in the exhaust gas re-circulation system, so where the valve screws are located oil pressure lubed? I think a much greater chance of either being sucked into the compression chamber and with any luck out the exhaust or has had happened into the pistons and valves doing damage?
 
#72 ·
Did it buck before EGR replacement? I believe I have asked this before but have both fuel filters been changed? My Duramax would shift crazy, buck, rev high, no power, when fuel filter was plugged.
 
#74 ·
It could really be as something as simple as the filters. Diesel is a very very dirty fuel.

There are 2 filters on this truck, one next to fuel tank, one in the engine bay. I would change both.

Does it buck when your get on the throttle a little bit?
 
#75 ·
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 05/18/19)

Current status as of 05/18/19:
 

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