Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread

[iceman77]

this is the only part number i can visibly see. and 90 mins post-driving, everything is bone dry. not so much as a drop of anything anywhere.

edit: does anyone know where it would say -V/W or -S?

That is exactly the same product number I have on my existing pipe. I have my doubts Ford has redesigned this part at all. They just changed the P/N in their system and shipping out the same units.
I, personally, am done with this sh*t. The heat exchanger is going bye-bye. Already talked to a muffler shop. They will cut it out and weld a straight pipe there. Guess what, they ask $60 for it!
I will bypass the coolant lines, only thing I still need to figure out is the PCM, that will complain about missing heat exchanger valve. I am working on disabling it via a PCM tune. Once that is done, no more heat exchanger for me, that means no more leak, and yes, screw Ford's warranty.

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[iceman77]

On another note, when I purchased my '22, first thing I did, when I brought it home, to check for underbody sagging insulation, that was a recall on my '21 truck. Guess what, no underbody insulator for '22 trucks lol. That's one way fixing the issue long term, so I would not be surprised at all that on new, upcoming '23 trucks they would just remove the entire heat exchanger from the design. I don't see any value to it, no matter how I look at it.

 

[Severdog]

I, personally, am done with this sh*t. The heat exchanger is going bye-bye. Already talked to a muffler shop. They will cut it out and weld a straight pipe there. Guess what, they ask $60 for it!
I will bypass the coolant lines, only thing I still need to figure out is the PCM, that will complain about missing heat exchanger valve. I am working on disabling it via a PCM tune. Once that is done, no more heat exchanger for me, that means no more leak, and yes, screw Ford's warranty.

We who are (also) about to die, salute you.

 

[dmarkjohn]

That is exactly the same product number I have on my existing pipe. I have my doubts Ford has redesigned this part at all. They just changed the P/N in their system and shipping out the same units.
I, personally, am done with this sh*t. The heat exchanger is going bye-bye. Already talked to a muffler shop. They will cut it out and weld a straight pipe there. Guess what, they ask $60 for it!
I will bypass the coolant lines, only thing I still need to figure out is the PCM, that will complain about missing heat exchanger valve. I am working on disabling it via a PCM tune. Once that is done, no more heat exchanger for me, that means no more leak, and yes, screw Ford's warranty.

That is exactly the same product number I have on my existing pipe. I have my doubts Ford has redesigned this part at all. They just changed the P/N in their system and shipping out the same units.
I, personally, am done with this sh*t. The heat exchanger is going bye-bye. Already talked to a muffler shop. They will cut it out and weld a straight pipe there. Guess what, they ask $60 for it!
I will bypass the coolant lines, only thing I still need to figure out is the PCM, that will complain about missing heat exchanger valve. I am working on disabling it via a PCM tune. Once that is done, no more heat exchanger for me, that means no more leak, and yes, screw Ford's warranty.

I agree with you questioning whether this part was actually a redesign. I really don't think it was. My replacement looks exactly like old one, same part # stamped on it et... However, mine is not leaking at all and I have about 1200 miles on the new one while driving in all conditions. Given the experience of others I am now concerned that mine will eventually leak. With the # of trucks being out of commission for up to 2 months now you would think Ford would at least come up with a temp bypass fix until they can figure out permanent solution. Especially since the exchanger doesn't seem to add any material benefit to the overall operation of the truck.

 

[rhymeandreasons]

exactly...i mean i never did have a good feeling that it wouldnt happen again since there was zero mention anywhere of any dealer or @Ford Motor Company rep say this was a "re-designed" part.

it was always "this part is backordered". not, the original was defective, here's an updated part.

and why would a 12 mile drive, 4 of which were electric only, at 50mph or less with the climate control off, cause such a puddle but doing 75 on the highway with AC full blast leave no drops at all.

I agree with you questioning whether this part was actually a redesign. I really don't think it was. My replacement looks exactly like old one, same part # stamped on it et... However, mine is not leaking at all and I have about 1200 miles on the new one while driving in all conditions. Given the experience of others I am now concerned that mine will eventually leak. With the # of trucks being out of commission for up to 2 months now you would think Ford would at least come up with a temp bypass fix until they can figure out permanent solution. Especially since the exchanger doesn't seem to add any material benefit to the overall operation of the truck.

 

[Nasto]

I agree with you questioning whether this part was actually a redesign. I really don't think it was. My replacement looks exactly like old one, same part # stamped on it et... However, mine is not leaking at all and I have about 1200 miles on the new one while driving in all conditions. Given the experience of others I am now concerned that mine will eventually leak. With the # of trucks being out of commission for up to 2 months now you would think Ford would at least come up with a temp bypass fix until they can figure out permanent solution. Especially since the exchanger doesn't seem to add any material benefit to the overall operation of the truck.

exactly...i mean i never did have a good feeling that it wouldnt happen again since there was zero mention anywhere of any dealer or @Ford Motor Company rep say this was a "re-designed" part.

it was always "this part is backordered". not, the original was defective, here's an updated part.

and why would a 12 mile drive, 4 of which were electric only, at 50mph or less with the climate control off, cause such a puddle but doing 75 on the highway with AC full blast leave no drops at all.

Just spit-ballin', but could buggy software have a role here? If the floodgates were open and coolant flooded the exchanger, would it spillover?

 

[Nasto]

I agree with you questioning whether this part was actually a redesign. I really don't think it was. My replacement looks exactly like old one, same part # stamped on it et... However, mine is not leaking at all and I have about 1200 miles on the new one while driving in all conditions. Given the experience of others I am now concerned that mine will eventually leak. With the # of trucks being out of commission for up to 2 months now you would think Ford would at least come up with a temp bypass fix until they can figure out permanent solution. Especially since the exchanger doesn't seem to add any material benefit to the overall operation of the truck.

I remember my parts guy at the dealer saying a different part number either meant a new supplier or the same supplier making adjustments to the part. No idea if that qualifies as a "re-design".

Maybe the simplest explanation is that for every 100 replacements they churn out, a certain percentage are bad. Could be a quality control issue.

 

[Snakebitten]

I'm not shocked to find an overcomplicated component on my Porsche. Incredibly well built, but sometimes you just wonder why all the fuss.

The exhaust heat exchanger is just a bizarre answer to what nobody would have been confused about. A Hybrid takes longer to heat up the engine coolant. If you want heat that bad, use Sport Mode until you are warm.

I'm looking forward to Iceman overcoming the pcm expectations. Depending on what kind of code it throws and what the penalty for that code is, I'm not sure I would care about a perpetual DTC.

 

[iceman77]

I'm not shocked to find an overcomplicated component on my Porsche. Incredibly well built, but sometimes you just wonder why all the fuss.

The exhaust heat exchanger is just a bizarre answer to what nobody would have been confused about. A Hybrid takes longer to heat up the engine coolant. If you want heat that bad, use Sport Mode until you are warm.

I'm looking forward to Iceman overcoming the pcm expectations. Depending on what kind of code it throws and what the penalty for that code is, I'm not sure I would care about a perpetual DTC.

Honestly, its not the DTC itself that concerns me, but the CEL that comes up with it on your dash. But I will figure it out.

 

[Snakebitten]

One code?
Multiple?
I'm assuming a sensor of some kind is supposed to send an appropriate "signal" to the pcm?
A range of voltage?

You don't need to take the time to explain. I'm just thinking out loud without putting in the necessary research. I'm guessing that there's a list of pinpoint test procedures in the service manual that might shed some light.

 

[rhymeandreasons]

dropped it back off just now and back in a rental. ill keep you posted of the diagnosis.

the tech said all the Ford Hybrids have a heat exchanger and this is Ford's description of it:

 

[Snakebitten]

Well if Ford puts these in all their Hybrids, then they have been designing them for many years.
Even more disturbing at the obvious fail on the Powerboost.

Having said that, mine is 12 months old and the company Powerboost is 13 months old and neither leak. And there's now 70,000+ Powerboosts (100,000 even?) and so only a tiny fraction leak so far?

All we can do is guess. Is it a manufacturer defect in the plastic composition? Or is it inevitable that they all will leak?

One interesting data point is that it seems most of the leakers are extremely low mileage. That would imply QC problems, no?

 

[Cuse0307]

Hi there! This doesn't sound like an experience we want you to have with your F-150. Could you please send us a PM with your VIN and the name and location of your Ford dealer? I'd be happy to see how I can assist you on my end.

Garbage Post. Your rep's can't even tell me what place I am in line for this issue and keep repeating your company call center script. My truck has been sitting for 10 days and you guys gave me a shtty 2018 Chevy Trax as a rental that is leaking air in one tire.

 

[rhymeandreasons]

i think you're arguing with a bot ?

Garbage Post. Your rep's can't even tell me what place I am in line for this issue and keep repeating your company call center script. My truck has been sitting for 10 days and you guys gave me a shtty 2018 Chevy Trax as a rental that is leaking air in one tire.

 

[Nasto]

dropped it back off just now and back in a rental. ill keep you posted of the diagnosis.

the tech said all the Ford Hybrids have a heat exchanger and this is Ford's description of it:

Thank you for keeping us updated!

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