Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread

[Snakebitten]

Here is the code information

In my opinion, they are following the procedure in the factory service manual that was written PREVIOUS to the CSP.

Or put another way, early on with the exhaust heat exchanger related issues, Ford would replace the "intermediate" exhaust pipe if ANYTHING was not performing perfectly. If the $5 coolant tube was leaking, Ford replaced the whole intermediate exhaust pipe. If the exhaust valve solenoid threw a DTC, Ford would replace the intermediate exhaust pipe.

It was a shameful wasted of time and resources, but typical of a huge corporate bureaucracy.

Here is the instructions that I believe your dealership is BLINDLY following.

This is the pipe:
(Note: Ford has since made the tubes (red circle) and the solenoid (blue circle) available separately, thus no longer needing to replace the whole exhaust pipe assembly

I personally believe that the CSP is intended to override the pinpoint test procedure conclusion in the service manual. Certainly if the real issue (DTC) is solved by replacing either the coolant tubes (leaking coolant) or the exhaust valve solenoid.

I'm sure that it is possible to have an issue with the exhaust heat exchanger assembly that is NOT either a leaking coolant tube and/or the exhaust valve actuator-solenoid. But I can't give the technician the benefit of the doubt that they would KNOW the DTC P2C22 isn't a malfunctioning solenoid.

By the way, if condensation in the exhaust valve freezes during cold temps, the DTC can be triggered because the valve is frozen. In just a few minutes, the exhaust melts the frozen condensation and the valve becomes functional again. So you'd have to clear the DTC and then verify whether it returns or not.
Only applies to you Northern Powerboost folks, of course.

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[mmccor]

Extremely helpful. I'm going to go to the dealership and see what we can get sorted out. Thank you again. If it doesn't work at this dealership, I'll be going to the dealership where they've actually serviced my vehicle properly in the past. May just do that anyways...

 

[Tamu05]

So after 5 weeks at the dealership, they're saying that the exhaust pipe has to be replaced because the baffle is broken and the actuator is falling apart, and it’s not covered by my ESP or the 24N04 program.

I originally brought it in after getting the P2C23 Heat Exchanger Bypass Valve code.

Could anyone help me understand why this would not be covered?

 

[Snakebitten]

If they are presenting this as an exhaust pipe and nothing but an exhaust pipe, then it is disingenuous at best.

Very much a Hybrid component. If it wasn't a Hybrid vehicle, it wouldn't be equipped with an exhaust heat exchanger to rapidly heat up engine coolant with an engine that only runs briefly because it's a Hybrid.

I thought ESP is written in a manner where EVERYTHING is covered except what is specifically listed as an exception. I don't remember the exhaust heat exchanger being listed as an exemption.

 

[Kodiak]

So after 5 weeks at the dealership, they're saying that the exhaust pipe has to be replaced because the baffle is broken and the actuator is falling apart, and it’s not covered by my ESP or the 24N04 program.

I originally brought it in after getting the P2C23 Heat Exchanger Bypass Valve code.

Could anyone help me understand why this would not be covered?

Which ESP did you buy? Was it the Official Ford Premium ESP (which you should have bought) or a lesser Ford ESP? Maybe even a 3rd party ESP presented by some dealers as "kind of official". Run from these 3rd party ESP's and only stick with the Ford Premium ESP. You can get these from Granger or other reputable online sellers of official Ford ESP's.

As Snake pointed out in the above post, with the official Ford Premium ESP there is only a small list of items that are not covered. This is the type of ESP you want, where it clearly states what is not covered so everything else is covered. Good luck.

 

[Porpoise Hork]

Agreed, not sure which dealer he took it to but this sounds like the typical crap Auto Nation Ford in Katy tries to pull.. They are notorious for claiming items that are clearly covered by warranty are not or wants you to pay diagnostic fees for warranty work. Even on brand new 80K trucks with less than 1K miles on them they try to pull this crap with.

Either the dealer is attempting to make money off this instead of properly honoring Ford's hybrid component warranty which is 8 years /100K miles. Or presented it incorrectly to your ESP which is denying the claim based on this or they just plain suck. I'd definitely try talking to the service manager about it and show them Ford's documentation on the Hybrid components warranty including the link from the NHTSA.gov and if they still try to deny it then take it to another dealership. You may also consider contacting Ford customer Care about it and get them involved if the dealer still refuses to budge. 1-800-392-3673

https://static.nhtsa.gov/odi/tsbs/2024/MC-11008403-0001.pdf

This is what Perplexity has to say about it.

Hybrid Components

8 years / 100,000 miles

Covers battery, electric motor, and other hybrid-unique elements

The exhaust heat exchanger (EGHR) on the Ford F-150 PowerBoost hybrid is covered by a special, extended warranty—specifically, Ford's Customer Satisfaction Program 24N04 provides a one-time replacement of the EGHR system for 15 years or 150,000 miles, whichever comes first. This coverage is automatically transferred to subsequent owners within its term and specifically addresses failures from water ingress or coolant leaks related to the EGHR system.

Coverage Details

• EGHR Special Coverage (CSP 24N04)
  This program covers EGHR failures for 15 years or 150,000 miles starting from the warranty start date on affected 2021–2023 F-150 PowerBoost Hybrid vehicles.
• One-Time Repair Rule
  The program allows for a single replacement if the EGHR system fails due to covered reasons.
• Transferability
  The EGHR coverage transfers to new owners and is valid for qualifying vehicles during the special program period.

Additional Warranty Insights

• The EGHR is typically not specified in the standard hybrid component warranty (8 years/100,000 miles), but this extended program addresses the most common exhaust heat exchanger failures directly.

Standard powertrain and emissions warranties may provide partial coverage depending on the cause, but the 24N04 program is more comprehensive for the EGHR.

https://www.grangerfordprotect.com/blog/ford-f-150-hybrid-warranty-explained/

 

[Tamu05]

So after 5 weeks at the dealership, they're saying that the exhaust pipe has to be replaced because the baffle is broken and the actuator is falling apart, and it’s not covered by my ESP or the 24N04 program.

I originally brought it in after getting the P2C23 Heat Exchanger Bypass Valve code.

Could anyone help me understand why this would not be covered

 

[Tamu05]

I did get the 7yr/125K mile warranty through Ford. After reading the fine print, the exhaust system is one of the exclusions.

Porpoise Hork hit he nail on the head with the dealership. Pretty impressive

 

[Porpoise Hork]

Knew it...

Take it to another dealership. Auto Nation Ford will do everything they can to scam customers out of money for warranty service. My father-in-law took his 25 platinum PB to them with 700 miles on it and was only 3 weeks old because it flagged an ABS issue. They wanted to charge him 160 diagnostic fee and tried to claim no warranty coverage for it saying it was a wear item. When he refused to pay it they tried to deny letting him get the truck back until he paid them. He absolutely lost his shit and went to the GM about it right there on the spot. Raised such a stink that they "waived" the fee and let him take the truck. Turns out the issue was caused by a the 12v battery state of charge being excessively low and the related modules failing to boot correctly at start. I fixed it by charging the battery and setting the SOC to 98% with Forscan.


While the exhaust itself is not covered by the ESP the heat exchanger most certainly should be covered by either the hybrid components or possibly the emissions-related parts warranties. Both have a 8yr / 100K warranty on them.

https://www.ford.com/cmslibs/conten...id-Warranty-version-2_frdwa_EN-US_07_2020.pdf

I'd also seriously consider contacting Ford customer care as well as Ford Premium Care (if that's the one you purchased) about it. If they are able to assist and get another dealership to cover the part under warranty then file a complaint against Auto Nation Ford with the BBB as well as with Ford Corporate.

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