nchighcountry
New member
Myself: I first reported this issue to Ford in September 2014 at 4100 miles on a new Super Duty F350 3 months in. It is right at a year later, and still no resolution. To deal with the issue, as soon as I go into active regeneration, I immediately drop gears from 6 to 4 or 5 to 3. This apparently increases the Mass Air Flow or pressure and keeps the valves from sticking and jack hammering.
I drive all of my regenerations to completion and use the ForScan App to proactively monitor my truck and all regeneration parameters (Regen On/Off, Soot Grams per Liter, Soot %, EGT Back Pressure, EGT 1 EGT2 EGT3 EGT4, injector fuel flow, distance since last regen, etc etc).
I never let my truck idle and cut it off as soon as I arrive at my destination.
I am a long term Ford Customer and the owner of a 2005, 2008 and 2011 prior to the 2015. The 2008 and 2011 with Active Regeneration never had this issue with the valves.
I have a pending case with Ford with no resolution.
In my opinion, based on diesel techs that have more knowledge than myself as a consumer, this issue is clearly related to valve clearance tolerance issues with the valve guides and head. When exposed to the high heat of regeneration, they expand and hang causing the valves to jackhammer.
This respected diesel professional also gives a clear explanation to what is occurring:
http://powerstrokearmy.com/forums/showpost.php?p=1272316&postcount=13
My comments as a customer dealing with this issue for a year now with no resolution from Ford:
Level Set on the Issue:
This is a factory engine manufacturing defect related to valves and valve guide clearances that generally shows up around 4000 miles.
Ford Engineers have met with some owners directly.
The customer who purchased two 2015 super duties that are both heavy haulers and used in ranch work, with one having the issue one not having the issue:
"He reviewed the data logs off our truck and did confirm that there is a problem occurring during regen (even though the cleaning exhaust filter message never displayed during any of the captured events).
I had a lengthy discussion with Mitch, the service manager and the owner of our dealer. The engineer has confirmed that there is NO fix and Ford does not know exactly what is causing the problem.
He indicated that we could pursue replacing valves or left head assembly on our truck but it would only be a "temporary" fix and the problem will reoccur.
He stated they were several trucks in which they have replaced the entire motor and the problem still returned.
He said they are working on some type of a programming/calibration update to be released "sometime" in 2016 but still couldn't guarantee me that it would solve the issue!
Basically, it's a problem, Ford knows it's a problem and there is no guaranteed fix or timeline for a fix"
If your engine valves have the issue, it will occur when you tow and don't tow and regardless of the way you drive your truck.
Only thing that may fix it is to have the complete left head assembly replaced and hope you get a new one with acceptable manufacturing tolerance levels. Make sure you get a complete assembled head assembly.
Any PCM reprogramming fix to resolve the issue in 2nd quarter 2016 is wishful thinking. It may try to mask the engine valve defect, but will never fix it.
Many of us have been slow rolled By Ford and yes this will hurt the resale value of your truck.
When buying a new 2015 / 2016 Super Duty it is recommended you have a firm understanding with the Sales Manager on how they will address your problem in service should you be one of the unfortunate ones to get an engine with the valve quality tolerance defect.
It is still a superb truck, and you should still buy one if you want one but you should be prepared to accept the risk that your engine may have valves that are out of quality tolerance levels and you will be on your own without the support of your dealer to help you get Ford to buy the truck back. It is unfortunate after a year on the 2015s that Ford has not issued a recall to address this issue.
The only thing that will support that is that if you have had an issue towing or not towing in traffic, and your valves have jackhammered in regeneration with the truck losing power, you should promptly document each occurrence of the issue on the NHTSB site for them to investigate the issue on behalf of all owners.
https://www-odi.nhtsa.dot.gov/ivoq/
The repair order below is from a 2015 owner who was fortunate to get Ford to replace the entire left head of his engine. After 11,000 miles, for this customer, the fix has thankfully been successful.
This repair order has had several thousand views on other forums.
I drive all of my regenerations to completion and use the ForScan App to proactively monitor my truck and all regeneration parameters (Regen On/Off, Soot Grams per Liter, Soot %, EGT Back Pressure, EGT 1 EGT2 EGT3 EGT4, injector fuel flow, distance since last regen, etc etc).
I never let my truck idle and cut it off as soon as I arrive at my destination.
I am a long term Ford Customer and the owner of a 2005, 2008 and 2011 prior to the 2015. The 2008 and 2011 with Active Regeneration never had this issue with the valves.
I have a pending case with Ford with no resolution.
- Some Customers have had valves replaced with the problem usually returning.
- Some Customers have been fortunate to have gotten a full left head replacement approved (the only possible way to successfully fix the issue)
- Some Customers have gotten cash buy backs
- Some Customers have been given a new truck at no cost (even swap)
- Some Customers have been given a 200,000 mile extended power train warranty that should also cover the emissions components.
In my opinion, based on diesel techs that have more knowledge than myself as a consumer, this issue is clearly related to valve clearance tolerance issues with the valve guides and head. When exposed to the high heat of regeneration, they expand and hang causing the valves to jackhammer.
This respected diesel professional also gives a clear explanation to what is occurring:
http://powerstrokearmy.com/forums/showpost.php?p=1272316&postcount=13
My comments as a customer dealing with this issue for a year now with no resolution from Ford:
Level Set on the Issue:
This is a factory engine manufacturing defect related to valves and valve guide clearances that generally shows up around 4000 miles.
Ford Engineers have met with some owners directly.
The customer who purchased two 2015 super duties that are both heavy haulers and used in ranch work, with one having the issue one not having the issue:
"He reviewed the data logs off our truck and did confirm that there is a problem occurring during regen (even though the cleaning exhaust filter message never displayed during any of the captured events).
I had a lengthy discussion with Mitch, the service manager and the owner of our dealer. The engineer has confirmed that there is NO fix and Ford does not know exactly what is causing the problem.
He indicated that we could pursue replacing valves or left head assembly on our truck but it would only be a "temporary" fix and the problem will reoccur.
He stated they were several trucks in which they have replaced the entire motor and the problem still returned.
He said they are working on some type of a programming/calibration update to be released "sometime" in 2016 but still couldn't guarantee me that it would solve the issue!
Basically, it's a problem, Ford knows it's a problem and there is no guaranteed fix or timeline for a fix"
If your engine valves have the issue, it will occur when you tow and don't tow and regardless of the way you drive your truck.
Only thing that may fix it is to have the complete left head assembly replaced and hope you get a new one with acceptable manufacturing tolerance levels. Make sure you get a complete assembled head assembly.
Any PCM reprogramming fix to resolve the issue in 2nd quarter 2016 is wishful thinking. It may try to mask the engine valve defect, but will never fix it.
Many of us have been slow rolled By Ford and yes this will hurt the resale value of your truck.
When buying a new 2015 / 2016 Super Duty it is recommended you have a firm understanding with the Sales Manager on how they will address your problem in service should you be one of the unfortunate ones to get an engine with the valve quality tolerance defect.
It is still a superb truck, and you should still buy one if you want one but you should be prepared to accept the risk that your engine may have valves that are out of quality tolerance levels and you will be on your own without the support of your dealer to help you get Ford to buy the truck back. It is unfortunate after a year on the 2015s that Ford has not issued a recall to address this issue.
The only thing that will support that is that if you have had an issue towing or not towing in traffic, and your valves have jackhammered in regeneration with the truck losing power, you should promptly document each occurrence of the issue on the NHTSB site for them to investigate the issue on behalf of all owners.
https://www-odi.nhtsa.dot.gov/ivoq/
The repair order below is from a 2015 owner who was fortunate to get Ford to replace the entire left head of his engine. After 11,000 miles, for this customer, the fix has thankfully been successful.
This repair order has had several thousand views on other forums.
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