Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread

[Nasto]

If this issue was first reported here last month and these trucks have been out for over a year and only a few members have had this issue so far, then stating that, "they knew the ... trucks had a high failure rate of this part over the entire fleet" is a bit of a stretch.

On March 8th, I posted about this thread I found from 2021:

https://www.f150gen14.com/forum/thr...oost-—-light-green-fluid-leak-under-cab.4279/

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[rhymeandreasons]

agreed....there's no way this doesn't turn into a Recall.

My dealer on Friday said basically the same thing; the number of people requesting new exhausts has exceeded 600 he said.

On March 8th, I posted about this thread I found from 2021:

https://www.f150gen14.com/forum/threads/2021-f150-powerboost-—-light-green-fluid-leak-under-cab.4279/

 

[Nasto]

agreed....there's no way this doesn't turn into a Recall.

My dealer on Friday said basically the same thing; the number of people requesting new exhausts has exceeded 600 he said.

I wonder if that 600 number is combined V + W parts or just W, since 5.5 foot bed owners were outpacing the 6.5. In any case, we're going through the pain now by staying ahead of any recall. Who knows what the wait time will be then for everyone else?

 

[RalpL]

Guess it's time for us to start filing massive numbers of complaints to the NHTSA.

Edit: Just went to their website. They want my VIN to start the complaint. I would do it, but I haven't even taken delivery yet. It's at the train depot an hour from the dealer still waiting for a convoy truck. So, I don't know if I'm affected yet as a 1/25 build. Oh well - I tried.

 

[Nasto]

When I first took it off the truck, I got quickly discouraged when I noticed the nuts welded to the bottom of the tray. But this time, after closer inspection, I noticed, the inlet pipes are detachable, and the top lid just pops off! That exposes the inner structure of the heat exchanger. the entire plastic part can be taken off, and replaced. so is the valve.

The source of the leak is the inlet pipe holes, they are deformed (perhaps due to manufacturing defect, or wrong material used, that deformed by heat). The holes are oval shaped, instead of perfect circle, and the coolant seeps through. I pressure tested the entire unit once I removed it from the truck and that's where the liquid seeped through.

I tried to replace the o-rings for larger one, but the deformation is bad, and it merely slowed down the leak. I will try to use some silicon gasket sealant (used for water pump housing assembly) as my next try. If that does not fix the leak, than hell with it, all the plastic part comes off, I leave the valve connected (so PCM does not complain about it) and I just bypass the coolant hoses (just as I did it before). That will for sure take care of the business!

Is the full part number stamped anywhere on the exchanger or exhaust pipe that is somewhat visible to anyone who wants to know what version they have?

 

[iceman77]

@Oxford_Powerboost or anyone having the CEL due to heat exchanger valve failure, this is what you need:

 

[iceman77]

Is the full part number stamped anywhere on the exchanger or exhaust pipe that is somewhat visible to anyone who wants to know what version they have?

Yes! My exhaust inlet pipe is still on my bench, I’ll snap a pic of it when I get home

 

[iceman77]

Here’s another view of my heat exchanger assembly after top lid removed. Notice all the fluid especially around the inlet pipe hole

Initially i suspected the leak around the valve assembly, but as you can see, its completely dry there. So is the pan.

I have also removed and inspected the plastic part that connects to the tray, no cracks or any other anomalies found. The tray sealing gasket looks good as well

 

[iceman77]

One more note about the bypass valve! (@Snakebitten you will be interested in this one!):

It does not bypass the coolant, it bypasses (or redirects) the hot gasses from the exhaust pipe into the heat exchanger radiator.

 

[Snakebitten]

One more note about the bypass valve! (@Snakebitten you will be interested in this one!):

It does not bypass the coolant, it bypasses (or directs) the hot gasses from the exhaust pipe into the heat exchanger radiator.

So if there was some way to prevent exhaust gasses from being directed to the heat exchanger, do you think that the heat exchanger could stay below the plastic-melting temperature?

I just want you to know that your efforts have helped me to be unconcerned about the new truck having a faulty heat exchanger.
Nor do I have to worry about drooping heat shields on the driveshaft.

So I think I'm down to just crossing my fingers that I get a decent example of the 10r80. I've been lucky with 2 good ones in a row, so maybe I can pull off the hat trick?

 

[iceman77]

Is the full part number stamped anywhere on the exchanger or exhaust pipe that is somewhat visible to anyone who wants to know what version they have?

This is for the short bed though

 

[Snakebitten]

That's definitely enough information stamped into the part itself to track supplier/batch I'm guessing?

 

[RalpL]

I guess I'm a bit confused. I thought we were looking for a part that ends in either "V" or "W" replacing one that ends in "S". This ends in "F". If I look under my truck when I take delivery later this week (hopefully), will I be able to tell if I have a potential future problem ("S") or already have the new part ("W")?

 

[Snakebitten]

I guess I'm a bit confused. I thought we were looking for a part that ends in either "V" or "W" replacing one that ends in "S". This ends in "F". If I look under my truck when I take delivery later this week (hopefully), will I be able to tell if I have a potential future problem ("S") or already have the new part ("W")?

Iceman is doing R&D on his existing faulty piece

 

[RalpL]

Iceman is doing R&D on his existing faulty piece

Thanks - it's actually quite interesting. So if I crawl under my new truck, will I be able to see the heat exchanger part number?

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