Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread

[TN Rotty]

I'll throw in my theory based on observations, but is probably totally wrong, so feel free to punch holes in it. When I went to the dealer to check on my truck on March 24th, there was a small, mostly dried coolant stain on the pavement (attached picture).

The battery was dead, so I used a portable jumper to get it to turn over. Of course, it only had enough juice to start in electric mode for a couple of minutes. I then looked under the truck again and it looked like a river of coolant streaming out (attached video).

So, if this whole exchanger contraption is for "comfort" as others here have discovered, it seems that upon starting the truck in electric mode, it immediately pumps coolant to the ICE in case you need cabin heat? Since it has been determined that the culprit on mine was a cracked valve, that's why it was leaking. Have you started your truck at all on those days you mentioned?

It IS easier to figure out when your case worker will update you. I had mine pinned down to once a week on Fridays! ?

I've started mine every weekday and driven it ~50 miles daily. I usually don't (really almost never) use the AC or heat (since owning the truck - moderate temps, or the heated seat is enough). It's possible I have a small leak during driving. It's just the varying amounts in the tray under the truck each morning that is interesting that I can't figure out a reasoning for. I've also had a negligible amount lost each day (unless the dealer did fill the correct tank and I lost quite a bit driving in two days and then not very much at all the next few days).

As far as an update from the case worker I have only one data point - the initial email. I emailed back and no reply from them now for 3 weeks. Which is fine, because if all they can do is call the dealer, they are of no use to speeding the process along (in fact they could hinder it).

Glad @Nasto got your truck fixed but bummer that it is 2 different parts depending on the bed length. I wish I knew what spot I was in that 571. There has to be someone in this world that knows when the expected manufacturing date for these backordered parts will be. Any info would be better @Ford Motor Company

Yep - I'm glad I'm in the shorter list (assuming an equal # of parts being produced in each grouping).

Is this the V part or the W part ? What is the dealer going to do with it ? Discard it ?

If it's the W, I would be interested having it! I think I can have that broken inlet pipe fixed!

Curious to get your thoughts on the longevity of this part (plastic coolant component fused to the metal tail exhaust). I'm thinking your repair would last longer than the part in general.

(I really hope the new part lasts for obvious/selfish reasons.)

Sponsored

 

[rhymeandreasons]

i would agree with that....when i was driving it, the overheats would occur more frequently in electric mode.

I'll throw in my theory based on observations, but is probably totally wrong, so feel free to punch holes in it. When I went to the dealer to check on my truck on March 24th, there was a small, mostly dried coolant stain on the pavement (attached picture).

The battery was dead, so I used a portable jumper to get it to turn over. Of course, it only had enough juice to start in electric mode for a couple of minutes. I then looked under the truck again and it looked like a river of coolant streaming out (attached video).

So, if this whole exchanger contraption is for "comfort" as others here have discovered, it seems that upon starting the truck in electric mode, it immediately pumps coolant to the ICE in case you need cabin heat? Since it has been determined that the culprit on mine was a cracked valve, that's why it was leaking. Have you started your truck at all on those days you mentioned?

It IS easier to figure out when your case worker will update you. I had mine pinned down to once a week on Fridays! ?

 

[Nasto]

I've started mine every weekday and driven it ~50 miles daily. I usually don't (really almost never) use the AC or heat (since owning the truck - moderate temps, or the heated seat is enough). It's possible I have a small leak during driving. It's just the varying amounts in the tray under the truck each morning that is interesting that I can't figure out a reasoning for. I've also had a negligible amount lost each day (unless the dealer did fill the correct tank and I lost quite a bit driving in two days and then not very much at all the next few days).

As far as an update from the case worker I have only one data point - the initial email. I emailed back and no reply from them now for 3 weeks. Which is fine, because if all they can do is call the dealer, they are of no use to speeding the process along (in fact they could hinder it).




Yep - I'm glad I'm in the shorter list (assuming an equal # of parts being produced in each grouping).



Curious to get your thoughts on the longevity of this part (plastic coolant component fused to the metal tail exhaust). I'm thinking your repair would last longer than the part in general.

(I really hope the new part lasts for obvious/selfish reasons.)

I'm really hoping that Ford either found a new supplier for that part or ordered a design change from current supplier. You would think they did since the part number changed.

I originally thought the case worker was dealing with things more on their end but a week ago it became apparent that they mostly just call the dealer. That's why I went in and spent 30 minutes talking with the parts dept last Saturday and they found a way to the part. My service rep also came through. I was impressed when I stopped by one day out of the blue and he showed me he keeps my FOB right in front of him on his desk and checked with parts everyday. I asked him how he gets through the day in this climate and he says when he gets home, he cracks out the whiskey. So, we started talking about that. Needless to say, both he and my parts guy are getting a little gift tomorrow when I pick up the truck. 40 days from start to finish. Seemed longer! This is the picture they have at the parts window.

 

[spikerS]

Well, I am now 60 days waiting for the part. Ford Customers Service says the part is now "shipped" but still no idea when it is going to arrive at my dealer...

I just want my check engine light to be gone. I paid a lot of money, I would like my truck to be 100%.

 

[Nasto]

I


Is this the V part or the W part ? What is the dealer going to do with it ? Discard it ?

If it's the W, I would be interested having it! I think I can have that broken inlet pipe fixed!

Wow. It looks sheared off. How does that happen if properly packaged? N/M. Just answered my own question.

 

[F150Novice]

Just picked up my truck from the dealer. It was exactly 25 days from the day I dropped it off to today. Hopefully things are starting to speed up for others that are waiting.

 

[Nasto]

Just picked up my truck from the dealer. It was exactly 25 days from the day I dropped it off to today. Hopefully things are starting to speed up for others that are waiting.

Actually, 25 days might be record time. Now that the old -S part is out of the system, plus more newer parts seemingly in transit, I would think wait times would improve IF more PowerBoost owners aren’t discovering leaks.

 

[SPARKY150]

Update: today I took my truck in for a completely separate issue that just occurred unrelated to the exhaust heat exchanger. But while I was there he gave me an update on the part and it is supposed to be released on 04/04/22. So that’s the good news from today, bad news is my truck is going to be getting a new turbo at 9000 miles! I went into detail on a new thread I made.

 

[mhillis]

Update: today I took my truck in for a completely separate issue that just occurred unrelated to the exhaust heat exchanger. But while I was there he gave me an update on the part and it is supposed to be released on 04/04/22. So that’s the good news from today, bad news is my truck is going to be getting a new turbo at 9000 miles! I went into detail on a new thread I made.

Which part number is showing it’s releasing on the 4th? Did your parts department give you that info or Ford?
My dealer just put me in a new f150 XL as a rental until mine is fixed. It not my lariat with powerboost but so much better than the Ford Edge. It’s also interesting to see all the differences. The 2.7l ecoboost is not bad but the 3.5 with powerboost has so much more kick

 

[Nasto]

If anyone is curious, here was the replacement i received over 3 weeks ago, but it arrived damaged in the box at the dealer like this.

I was assured i wouldn't be sent to the back of the line since my original request date for a new part was 2/18ish...but that doesn't seem to have made a difference.

So, is the piece he has in his hand considered one of the two valves, inlet or outlet?
I would love to know if they feel as cheap as they look.
If you zoom in, you can see a part number. Wonder if it's different than the original -S version.

 

[Snakebitten]

So, is the piece he has in his hand considered one of the two valves, inlet or outlet?
I would love to know if they feel as cheap as they look.
If you zoom in, you can see a part number. Wonder if it's different than the original -S version.

I don't think the broken piece is a valve. Instead it is just one of the two coolant hose couplers. I THINK there is one valve and it is internal? X

Assuming the yellow lines are wiring, you can see what look like sensors in each coolant line upstream/downstream of the heat exchanger. I suspect that they are temp sensors and based on data from those sensors the valve opens/closes.
If you see the 3rd wire, it goes to the heat exchanger itself. Is that a power wire for an internal 12v valve? It's my best guess.

Ford mentions more than once that condensation can freeze inside the exhaust heat exchanger and prevent the valve from functioning properly and that the truck has to run for a bit to thaw out the ice.

Frozen plastic doesn't sound good for long-term functionality. Plastic doesn't do well with heat cycles that spread from ice to 220F, I don't think?

 

[Snakebitten]

If warranty wasn't at risk, I would couple the 2 hoses, bypassing the heat exchanger altogether.
But from what I have heard, you'd still need to "break" (disassemble) the plastic portion of the heat exchanger away because without coolant in it, the exhaust will just melt the plastic.

Of course none of that would address the pcm expectations of that valve being there to open and close, so I'd likely need a ghost valve similar to the clever pedestrian alert defeat device others have invented.

 

[Nasto]

I don't think the broken piece is a valve. Instead it is just one of the two coolant hose couplers. I THINK there is one valve and it is internal?

View attachment 44617

Assuming the yellow lines are wiring, you can see what look like sensors in each coolant line upstream/downstream of the heat exchanger. I suspect that they are temp sensors and based on data from those sensors the valve opens/closes.
If you see the 3rd wire, it goes to the heat exchanger itself. Is that a power wire for an internal 12v valve? It's my best guess.

Ford mentions more than once that condensation can freeze inside the exhaust heat exchanger and prevent the valve from functioning properly and that the truck has to run for a bit to thaw out the ice.

Frozen plastic doesn't sound good for long-term functionality. Plastic doesn't do well with heat cycles that spread from ice to 220F, I don't think?

Thanks for explain that. The reason I'm asking is that my service tech said the reason I had a leak was because of a broken plastic valve, which, if internal, would be hard to see unless they took the time to take it apart. I'm wondering if he meant a hose coupler. If one of those was broken, I wold imagine that would cause a leak as well. No matter. Going to the dealer today to pick it up!

 

[Nasto]

I am now concerned that my dealer is also looking for an older part. The Part number they gave me last week is ML3Z5A212W. I just searched and found parts.lakelandford.com listed my part number so I called to see if they had any in stock knowing it was a long shot. Of course they didn't and the guy on the phone looked up when they would be available and said the same thing my dealer is saying they are backordered and no idea when they will come in. He did read on his screen that it's a Nationwide backorder due to capacity issues that is being resolved. So whatever that means. I keep forgetting that I actually purchased a truck because I have been driving this Ford Edge for so long. I have also tried many times to open a ticket with Ford Directly but the number they gave me requires an extension. Then the extension they gave me says it is not recognized. Next they gave me an email address to open the ticket at Ford and that person gave me the exact same phone number and extension that does not work! Does anyone have an extension they have used and worked? Maybe they would be able to start a ticket for me or transfer me to the correct person.

Do you still need a working phone number and extension?

 

[Snakebitten]

Thanks for explain that. The reason I'm asking is that my service tech said the reason I had a leak was because of a broken plastic valve, which, if internal, would be hard to see unless they took the time to take it apart. I'm wondering if he meant a hose coupler. If one of those was broken, I wold imagine that would cause a leak as well. No matter. Going to the dealer today to pick it up!

I don't know if what he said is 100% accurate, or if he actually disassembled the plastic housing and verified REALLY what is failing in this sudden rash of leaky exhaust heat exchangers.
Personally I think it feels like a batch issue. Although the design might be so vulnerable that all batches can eventually fail?
And I personally don't believe technicians are being very invasive about getting to the root cause. They have zero incentive to. They are likely following typical warranty claim protocols and simply identifying the problem as a faulty component and replacing it. Afterall, that's all they will be paid to do.

Having said that, I would LOVE to get my hands on just one of the failed heat exchangers. I'm almost nerd enough to buy one, but that would be so unfair to one of my Powerboost brothers who is without his truck.

Sponsored