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

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54K views 110 replies 20 participants last post by  xDiesel  
#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
 
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#77 · (Edited)
On another note that is not related to this site but still I find it funny
My 2014 Ford F250 regular cab diesel plow truck has thrown its first check engine light at 60,000 miles brought it to the dealer to get checked and sure enough EGR below threshold lol
No warranty left on that truck so I ordered a bully dog programmer and DPF delete pipe I will delete all emissions on it as I will be keeping the truck and more than likely be driving it into the ground
 
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#78 ·
Yeah I just "upgraded" my buddies 16 F250 6.7 this weekend. We used Tyrant Tunes and a EzLynk. The 200+HP tune is NASTY!
 
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#80 ·
OK, just cleaned up my 2018 Bluejean 3.0 and off to the dealer to turn it in. Ford has been very good to work with during the buyback. I bought the truck in late January so this is a shorter timetable than others I have heard of. My first (and last!) buyback. By the way, this truck was perfect in every detail except for the bucking and related issues.

We are in the middle of a move so I will wait till we get settled to replace it. Probably going to get a Platinum 3.0 to get the features I want.
 
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#83 ·
That would certainly be unnerving... If somehow it made it past the exhaust, and through your turbo without causing damage to either (unlikely), you'd surely find it sitting upstream of your DOC. Maybe you can get under there and give it a shake? or pop it off and take a look inside. I doubt you will find it there tough.

In my opinion the most likely scenario is that it was still in or near the EGR valve, and it fell out and down when they took everything apart. If it made its way into a cylinder and bounced around in there enough to cause knocking, there certainly would have been valve damage, and you would see that in your compression test. If somehow it got pounded into a piston, I bet there would be a balancing issue that you would notice as a vibration in the engine. For peace of mind however, maybe get a second opinion on the compression test at an independent shop, and if if you really want to know, find someone to borescope the pistons to see if any of them show signs of damage... even if it was pounded into the head somewhere, you would see damage on the piston. If that comes back clean, you're likely good to go! If you're still worried after that... have the dealer give you a good deal on a trade in haha. Good luck!
 
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#84 ·
P245B EGR Engine Code

I took my truck on a long fishing trip last week. I filled it up with fuel and DEF today and when I put it in park in my driveway, it through a CEL: P245B. It seems to be running well and I didn't notice any issues. Has anyone experienced this? I'll be setting up an appointment with the dealership soon.


Appreciate any feedback others may have!
 

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#85 · (Edited)
duan0501 said:
I took my truck on a long fishing trip last week. I filled it up with fuel and DEF today and when I put it in park in my driveway, it through a CEL: P245B. It seems to be running well and I didn't notice any issues. Has anyone experienced this? I'll be setting up an appointment with the dealership soon.


Appreciate any feedback others may have!
Click to expand...
Definitely setup appt with dealer. I would also check connections to EGR under the hood. Be sure to post back what dealer says.

As your truck is a 2019 it should not be a issue with the EGR screw that could potentially fall out, should be all good there.
 
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#86 ·
Was able to get the truck into the dealership today. They stated on the phone the EGR Cooler went bad and they are replacing it. Should have the part in tomorrow. Are there any questions I should be asking them about this?
 
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#87 ·
Well, bad news from the dealer... My truck must've slipped through the assembly line with the old EGR cooler installed. I've never been made aware of a recall by mail or via the FordPass app. When the dealer took it apart, there was one missing screw, which hasn't been found.



The dealer claims that Ford told them to run certain tests and if it passes, to release the truck back to me. I'm of course very frustrated by this as the missing screw likely made it's way through the cylinder head and out the turbo... I'm working with the dealer I purchased the truck from (4 hours away) to see if there is any more they can do to communicate with Ford directly.
 
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#88 · (Edited)
@duan0501 - sorry to hear about your missing EGR By-pass valve screw, as this is the first I have heard of a 2019 model year being impacted.

If you haven't found this yet, here is the sticky thread for: START HERE: Any owners affected by FSA 18E02 (EGR By-pass valve replacement)
=> I recommend that you post on this sticky thread to get your vehicle added to "the list"
=> Or if you like I can merge this thread into that master sticky thread
Either way I will add you and your vehicle to the "Wounded Bretheren" spreadsheet of affected owners

I would be very interested if this was indeed any original/faulty EGR By-pass valve or the newer/re-designed EGR By-pass valve, but I'm not sure if the dealer would be able to provide that info, as your vehicle was not part of the FSA 18E02 recall. It would be scary if this was indeed the newer redesigned valve...
 
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#89 ·
duan,

What is the build date of your truck?
 
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#91 ·
Wow the Recall sheet on the EGR issue says trucks built after October 20 2018 should not be affected.
 
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#92 ·
@fharrison - any updates on your P2457 and P0234 codes?
 
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#94 ·
Sorry, didn't update. So truck was in shop over a month. They replaced the egr and still had an overboost problem. Replaced turbo, and that fixed overboost problem but it was really loud. So they replaced it again and it seems to be running good now. I guess a pin in the vgt actuator came loose. They then had an exhaust gas leak at the back of turbo donut connection. I still think it is leaking a little but barely. I hate donut connections. Have them on my snowmobile and you can never seal them without some kind of gasket maker. I might do a little sealer on the connection myself. Little nervous about any excess on the inside getting in the dpf. Running good now though.
 
#93 ·
FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 07/05/19)

Current status as of 07/05/19:
 

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#95 ·
A couple additional updates from the dealer that performed the EGR Assembly replacement. The assembly they replaced was P/N: JL3Z 9U438A. They replaced this with P/N: JL3Z 9U438B. This leads me to believe my truck somehow slipped through the assembly line, build date of February 4, 2019 (confirmed by Ford representative), with the recalled assembly.



I've created a case number with Ford as well as NHTSA and will continue to update as this progresses...
 
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#96 ·
@duan0501 - thanks for posting back with the specific before and after part numbers, as I think you have confirmed my suspicion...

duan0501 said:
A couple additional updates from the dealer that performed the EGR Assembly replacement. The assembly they replaced was P/N: JL3Z 9U438A. They replaced this with P/N: JL3Z 9U438B. This leads me to believe my truck somehow slipped through the assembly line, build date of February 4, 2019 (confirmed by Ford representative), with the recalled assembly.
Click to expand...
Original Ford Part numbers do not end in a letter, but Ford does use a letter suffix to indicate a part revision/supersede. How do I know this? Anyone else have issues with the needle bearings in the Front Wheel assembly on a Lariat or above trim level with AWD? I did once on my 2015 Ford F150 Platinum and my buddy at work just purchased a 2019 F150 because he went thru four (4) wheel assemblies on his 2016 F150 Lariat due to the noisy needle bearing. Last I checked, Ford was up to the "H" version of the Front Wheel assembly before I traded in my 2015 F150 Platinum.

Why am I going on and on about these revision suffixes? => Check out the part number on the 6th attachment in the original FSA 18E02 recall documentation that @wreedsvt posted here in this thread: Post #122 that I have attached and highlighted in yellow here: P/N: JL3Z 9U438A

@duan0501 just had his EGR By-pass valve replaced with P/N: JL3Z 9U438B
=> This tells me that @duan0501's truck came off the assembly line with the correct replacement P/N JL3Z 9U438A (P/N listed in the recall) at the time of manufacture
=> @duan0501's truck with the replacement part P/N JL3Z 9U438A just suffered an ingested EGR By-pass valve screw
=> This also seems to indicate to me that the replacement part we all got as part of FSA 18E02 suffers from the same problem as the original part; otherwise why is there a "B" version?
=> This will be the 1st question for my Service Manager when I bring my truck in on 07/11/19 for my FORScan code B148E - Front Camera issue

Here we go again...
 

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#97 ·
OK! I am all done finally. As you all may remember Ford agreed to buy my Blue Jean 3.0 Lariat and I turned it in to a dealer up north on May 30. I was promised everything would go quickly after that.

Flash forward to today. I never heard anything back on my check (it was a pretty big check) so finally I asked the BBB to reopen the case. Today BBB called and my check has been about a mile from my house for the last 20 days. It was at the local Ford dealer but no one informed me.

Anyway, still enjoying my new 2018 Platinum. And now, back to retirement.
 
#98 · (Edited)
Dunrollin said:
Flash forward to today. I never heard anything back on my check (it was a pretty big check) so finally I asked the BBB to reopen the case. Today BBB called and my check has been about a mile from my house for the last 20 days. It was at the local Ford dealer but no one informed me.

Anyway, still enjoying my new 2018 Platinum. And now, back to retirement.
Click to expand...
@Dunrollin - glad to hear everything finally worked out and you got an upgrade in the end. Not sure why the dealer sat on your check for 3 weeks, as that doesn't help anyone and causes more ill will.

Now let's see what I can find out today about this P/N: JL3Z 9U438A vs P/N: JL3Z 9U438B for the EGR By-pass valve...
 
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#99 ·
Here is EGR part info from fordpartsgiant.com does look like B replaced A, I am wondering if B is a update for something other than the screw. I find it hard to believe Ford would screw up that big.
 

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#100 ·
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#101 ·
Talked to my Service Manager regarding the P/N: JL3Z 9U438A vs P/N: JL3Z 9U438B EGR By-pass valve part numbers -- here's a summary:
  • He was unaware that there was a newer B P/N for the EGR By-pass valve assembly
  • He said there is no indication from Ford that there is anything wrong with the A part
  • He said he cannot do anything (e.g. replace my P/N: JL3Z 9U438A with a P/N: JL3Z 9U438B) until Ford tells him to do something
  • He told me we'd just have to keep a tight eye and ear on things
I'm not really surprised by anything he told me, though it doesn't give me a lot of confidence that the same issue could happen with the A part.

Sorry for the "non" post with not a lot of definitive information, but I think we'll just need to sit tight until Ford takes some corrective action and be aware that there is still a potential for the A part to have the same issue as the original part (as @duan0501 has proven)
 
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#102 ·
Sounds like you are tight with the service writer, could he show you an A part to confirm screws are welded in?
 
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#104 ·
Thanks! That should make us feel better! Hopefully duan's truck was a one off issue and the new "B" part number EGR was a fix for something else.
 
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#105 · (Edited)
Just thought I would revisit this thread (since the last update was ~9 months ago) to see where affected owners stand:
=> Working from the FordF150FSA18E02 "Wounded Brethren" spreadsheet (as of 07/05/19) update

@djman - any further issues after Ford putting you back together and sending you on your way?

@adamrbrg@yahoo.com - did Ford rebuild your engine from the short block or did they pack-it-in when they realized how much that would cost them?

@jevalek77 - any further issues after Ford putting you back together and sending you on your way?

@Bronc71 - where did you finally end up with your truck?

@Sprink - did Ford ever offer a buyback under the CT Lemon Law?

@duan0501 - any further issues since Ford replaced your EGR By-pass valve with the newer "B" revision part?

Not trying to rub-salt-in-anyone's-wounds, but more interested in where you ended up and if Ford made you whole...

Thanks in advance.
 
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#106 ·
Hi I'm currently going through this issue. 2019 f150 lariat. Went in for egr replacement 2 days later truck starts knocking loudly. Been at the dealership for 2 weeks and they can finally tell me there is damage to one of the pistons. Obviously this was caused by the egr screw being pounded into it. I live Canada and am wondering is anyone else with this issue up here was able to get their truck bought back it only has 25000km on it and I want nothing to do with a rebuild any info would help
 
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