This "sticky" thread is an attempt to:
What we (as fellow owners) know about FSA 18E02 (as of 03/28/19)
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
=> 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
- 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
What we (as fellow owners) know about FSA 18E02 (as of 03/28/19)
- 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)
- 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) - 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 - 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 - 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 - FSA 18E02 is a "no loaner car" FSA but some dealers are making exceptions
- Ford 3.0L V6 "Lion" PowerStroke Diesel engines are only manufactured/assembled in Europe at the Ford plant in Dagenham, UK
- 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
- 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
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
- 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 - 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)
- 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 - 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
- Ask to see the old EGR By-pass valve to ensure both screws are intact (maybe take a digital pic for your records)
- Ask for your RO to be updated to reflect #1
- 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)
- If you are missing one or both screws, please continue reading to determine your fate
- 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) - 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 - 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.
=> 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
