[jmperlik]

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)

 

[wreedsvt]

Sounds like you are tight with the service writer, could he show you an A part to confirm screws are welded in?

 

[RBaker]

Wreedsvt. I checked my parts list for the EGR by pass replacement. P/N: JL3Z 9U433 A was used and is the part in those pictures.

 

[wreedsvt]

Wreedsvt. I checked my parts list for the EGR by pass replacement. P/N: JL3Z 9U433 A was used and is the part in those pictures.

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.

 

[jmperlik]

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.

 

[Canadiandan]

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

 

[danbart]

I've been waiting for 3 months to get the recall done. Dealer says the EGR replacement valve is on backorder.

 

[danbart]

Finally got mine done yesterday. Paperwork says they installed 9U433-B, not 9U438-B.
Original ERG Valve was intact with both bolts and washer still in place.

 

[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.

 

[Dunrollin]

Some of the first posts here are amazing, yours is at the top of the list for sure. Hopefully you are close to the end of your long nightmare. This sounds very close to the issues I had with my first 3.0 diesel that Ford did buy back. Your issues are much worse than I faced. Has Ford made you a firm settlement figure or just a commitment to buy it back yet? What I am concerned with is the mileage cost- in my case I was at just over 3,000 miles but you are at 10 times that and it can eat into your settlement quickly.

In my case I felt Ford was good to work with, pretty helpful and responsive to the various issues. My big complaint was they sure took their time with the process.

 

[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.