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Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread

Snakebitten

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I have a FANTASTIC relationship with a few people at a particular dealership. So much so that I have purchased my Fords from them for just short of a quarter of a century.

But the service department?
I don't trust them one bit.
They lied straight to my face once just to sell me an air filter.
I was stunned.

I didn't even respond, but rather just stared at the service writer when he told me "the tech said he checked your air filter and it looks pretty bad"

After just looking at him........Dead in his eyes......... Not saying anything, he knew they had stepped in it. At least he was embarrassed. Perhaps there's hope for the young man. Lol

Nobody will ever find a dirty air filter in one of my vehicles. I'm just saying. 😁
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Grafx36510

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The guy that everyone b*&%ches to at work...
I have a FANTASTIC relationship with a few people at a particular dealership. So much so that I have purchased my Fords from them for just short of a quarter of a century.

But the service department?
I don't trust them one bit.
They lied straight to my face once just to sell me an air filter.
I was stunned.

I didn't even respond, but rather just stared at the service writer when he told me "the tech said he checked your air filter and it looks pretty bad"

After just looking at him........Dead in his eyes......... Not saying anything, he knew they had stepped in it. At least he was embarrassed. Perhaps there's hope for the young man. Lol

Nobody will ever find a dirty air filter in one of my vehicles. I'm just saying. 😁
I experienced a similar situation. So I asked them to show me the filter because I write the date and mileage on the filter when I change it. I got the same blank stare.
 

Recurve

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His dealer actually has some old school techs who know how to fix cars instead of shotgun blasting parts at it.

I talked to my dealer and they insisted that the exhaust pipe assembly also needs to be replaced despite the TSB stating the contrary. I sugesseted just trying to replace the o-rings or that I would be happy to supply the coolant line parts when they arrive. They also stated that unfortunately they can't accept "owner supplied parts on warranty repairs" even if they are still in the original packaging and are the correct parts. So I get to wait for Ford to get their act together and ship all the parts. So my wait could be weeks to months long depending on when they will finally supply replacement parts to the dealership. :confused:
That could very well be true. We are in a pretty rural area where word of mouth and reputation is a big deal. This is my first Ford, so I don't know these techs personally, but it has been a pretty good experience so far.

In case it helps anyone looking for parts or talking to their dealers, this is the part number on my invoice:

NL3Z-18663-A

It has "Tube - 852635" listed in the description and also says that they replaced it per "SSM 51134"

Best of luck to all those still waiting...
 

Porpoise Hork

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That could very well be true. We are in a pretty rural area where word of mouth and reputation is a big deal. This is my first Ford, so I don't know these techs personally, but it has been a pretty good experience so far.

In case it helps anyone looking for parts or talking to their dealers, this is the part number on my invoice:

NL3Z-18663-A

It has "Tube - 852635" listed in the description and also says that they replaced it per "SSM 51134"

Best of luck to all those still waiting...
I cited that TSB to my dealer and they still want to replace the exhaust pipe section as well despite the TSB stating its replacement is no longer needed. Got an update from Ford Customer Care today that Ford stating no ETA on when parts will be made available to complete my repair. It's anyone's guess and could be a week or 6 months.

If it takes more than another week or two I might get a wild hair and go to the dealer when the coolant fittings I ordered come either today or tomorrow, get my truck and fix it myself right there in their parking lot.
 

cpf150

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Having the same leak so went by the dealer. Of course, I have 37,101 miles so out of warranty. He checked stock in warehouse and they have 650 available so he ordered my $15 in parts and will call me next week to install. He expects .5 to 1 hour of labor plus coolant so I will likely have $150-200 in this. Has anyone replaced the elbows/tubes themselves and, if so, can it be done without removing the entire exhaust pipe/etc? I'm thinking it may be worth the labor fee to avoid getting covered in coolant......
 

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Porpoise Hork

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Service advisor just let me know that out of no where all the parts to fix mine (coolant fittings and exhaust pipe assembly) just arrived. They are going to get started on it within the hour and then heat cycle it a couple of times to make sure it's fixed. If all goes well I should have my truck back this afternoon.
 

Snakebitten

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Yea!
You've been a really good sport about the whole thing. I hope you are rewarded with 200,000 trouble free miles. 😁

(may as well reach if you are wishing, right?)
 

Porpoise Hork

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Just got home with the PB. Man I've missed the truck. They replaced both coolant lines and exchanger pipe. Road tested to bring it up to temp then let it cool down followed by pressure testing it to verify no leaks.


Yea!
You've been a really good sport about the whole thing. I hope you are rewarded with 200,000 trouble free miles. 😁

(may as well reach if you are wishing, right?)
The 5th gen Ranger definitely taught me to be patient with the back order parts thing. Still sucks to have to wait 23 days for this one, and something Ford still needs to work on but sure was nice to see them pull it up and hand me my key. Got in and to my surprise it still has that new truck smell. :D I guess I had gotten used to it when I dropped it off at the start of the month and no longer smelled it.
 

Kodiak

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FYI - I just received my order for 4 "TUBES" with the O ring on the end. I am not sure if that is the O ring that is causing some of the failures but there is an O ring on one end of these "tube-spouts".

Snake has a load and so do I now so if anyone has this failure, and the dealership says they cannot get this part, there are some people here with supplies to help out. Come to this post if they are needed. :)

Ford F-150 Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread DSC_0371.JPG
 

Porpoise Hork

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FYI - I just received my order for 4 "TUBES" with the O ring on the end. I am not sure if that is the O ring that is causing some of the failures but there is an O ring on one end of these "tube-spouts".

Snake has a load and so do I now so if anyone has this failure, and the dealership says they cannot get this part, there are some people here with supplies to help out. Come to this post if they are needed. :)

DSC_0371.JPG
I'm 99.9% certain that the o-ring on this fitting is the primary culprit to the issue. I also have two sets of these as well and plan on sizing the o-rings to get several sets of those to have on hand as well.

Same goes from me, if anyone is in need I can drop ship to you or meet up with you if you're in the Houston area.
 

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TN Rotty

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Having the same leak so went by the dealer. Of course, I have 37,101 miles so out of warranty. He checked stock in warehouse and they have 650 available so he ordered my $15 in parts and will call me next week to install. He expects .5 to 1 hour of labor plus coolant so I will likely have $150-200 in this. Has anyone replaced the elbows/tubes themselves and, if so, can it be done without removing the entire exhaust pipe/etc? I'm thinking it may be worth the labor fee to avoid getting covered in coolant......
I'm not sure if anyone has gotten beyond ordering the parts. If you do replace it yourself, take some picks and let us know how it went. Good luck and sorry about the 1.101k miles over warranty finding.
 

TN Rotty

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Congrats to @Porpoise Hork for getting his truck back. List as I have it: (let me know of changes)

NameBlendBed/ PartTold DlrMilesCan Drivepart orderedpart arrivedInstall DateIssues After?
Dan65 repair#1
12/22/21​
5.5/W
1/20​
166​
No
01/20/22​
3/17/2022 56 daysYES - ~5000 miles, in May leaking again
Rhymeand reasons
01/05/22​
5.5/W
2/16​
1990​
No
02/18/22​
3/9 - arrived damaged - re-ordered 3/9 - arrived 4/74/8/2022 51 daysNo!!!
Nasto
01/05/22​
6.5/V
2/22​
296​
NoWrong -S part ordered: 2/23/22. Re-ordered -V: 03/09/22.
3/29/2022​
3/30/2022 37 daysno
Cuse0307 repair#1
01/15/22​
6.5/V
3/19​
3300​
No
03/20/22​
5/13/2022​
5/13/2022 55 daysYES - 900 miles and leaking again
Bellin stoke
02/01/22​
5.5/W
3/23​
2600​
No----4/14/2022 22 daysno
Thunder chief
12/23/21​
5.5/W
3/28​
1237​
No
03/28/22​
4/25/2022​
4/26/2022 29 daysno
MTPower boost
12/06/21​
5.5/W
4/8​
3127​
No
04/06/22​
5/11/2022 33 daysNo - 150 miles so far
Matthyius
01/06/22​
6.5/V
4/18​
3930​
No
04/22/22​
scavenged off new truck in lot6/20/2022 63 daysNo - 2000 km so far FORD offering 3 month payments 8yr/180k km warranty
Deeds972MY226.5/V
5/9​
4800​
No5/23/2022 14 daysNo
Dan65 repair#2
12/22/21​
5.5/W
6/9​
5002​
No
06/09/22​
7/25/2022​
7/27/2022 48 days
emiantan
12/20/22​
5.5/W
6/16​
6728​
No (but kept at home for mods)
06/17/22​
7/27/2022​
7/27/2022 41 days1 month, 3000 miles good so far
PeaksFordMY225.5/W
6/28
4852
No
07/07/22
Truck traded out to dealer
70mach1
12/16/21​
5.5/W
6/22​
4500​
No??
7/29/2022​
7/29/2022 37 days
Zakloosle
12/17/21​
6.5/V
4/26​
2900​
No4/26/22?8/11/2022 107 days
Ford Driver
01/22/22​
5.5/W
3/29​
300​
No
04/22/22​
8/18/2022 142 days
jeepin95
01/11/22​
5.5/W
9/2​
4987​
No
9/9/2022​
9/16/2022 14 days
JLOYD98
03/15/21​
5.5/W
7/19​
13500​
No (CEL since 4/20)
7/22/2022​
10/11/2022 84 days
Daniel BocaMY 225.5/W
10/17​
1100​
No10/24/2022 7 days
Porpoise Hork
01/22/22​
5.5/W
3/1​
4706​
No3/24/2023 - 23 Days
--------------------------------------------------------------------------
Oxford_Po werboost
09/27/21​
5.5/W
2/7​
7600​
Yes
02/07/22​
5/20/2022​
5/25/2022 107 daysno
Dmark john
12/20/21​
5.5 W
2/21​
400​
Yes
02/21/22​
3/10/2022​
3/11/2022 18 daysNo- have 4K miles post repair and everything is good
iceman77
01/06/22​
5.5/W
2/22​
1707​
Yes
02/24/22​
4/21/2022​
4/23/2022 60 daysno - ~24.6k miles so far with no leaks
MrFarly repair#1
01/04/22​
6.5/V
4/8​
8000​
Yes
04/11/22​
5/11/2022​
5/12/2022 34 daysYES - @ 2500 miles leaking again
MrFarly repair#2
01/04/22​
6.5/V
6/6​
10900​
YesCorporate Ford tech expedited and looked at this 2nd leak
6/14/2022​
6/21/2022 15 days23.5k miles and still good
Sir Choppins
12/17/21​
5.5/W
6/2​
1200​
Yes06/06/22
7/11/2022​
7/12/2022 40 days
Boone
2/1/2021​
5.5/WMar 2022
20550​
Yes7/27/2022 ~4.5 months
TN Rotty
12/19/21​
6.5/V
3/1​
1100​
Yes
03/07/22​
7/21/2022​
7/28/2022 149 days4.5 months and watching a drop in reservoir
Cuse0307 repair#2
01/15/22​
6.5/V
6/6​
4200​
Yes
06/06/22​
8/6/2022 61 days
RyanC111
04/21/21​
6.5/V
4/7​
7694​
Yes
05/25/22​
8/17/2022​
8/22/2022 137 days
Klvanzu
01/16/22​
5.5/W
5/11​
3100​
Yes
05/11/22​
8/24/2022 105 daysover 3 months no issues since
Mosey
09/03/21​
5.5/W
8/15​
6500​
Yes - but left it9/1/2022 17 days
DB63
12/14/21​
5.5/W
3/14​
1000​
Yes
03/14/22​
9/9/2022​
9/13/2022 183 days
wayni
44577​
5.5/W
####​
1100​
Yes
44805​
9/12/2022 20 days
VRF201
01/22/22​
5.5/W
9/3​
6200​
Yes9/21/2022 18 days
Matthyius repair #2
01/06/22​
6.5/V
10/12​
17820 km10/13/20221 day wow
DadnkidJan 225.5/W
10/3​
1500​
10/18 ??No leaks at 100 miles
bobnweave13
03/01/22​
5.5/W
10/31​
2900​
Yes
RTF150Feb 225.5/ still diagnosing
11/7​
1850​
Yes???11/15/22 8 DaysMay have been inlets & outlets leaking
mbpJan 226.5 ft
11/30​
~655don’t want to risk it12/5/2022 5 Days
m_bt54
08/21/22​
5.5/W
12/21​
18000​
Yes, slow leak so far1/6/2023 16 Days - not heat exchangerMuffler inlet pipe replaced
SAAUZ
04/20/22​
5.4/W
1/13​
27000 km
1/20/2023​
1/20/2023​
1/23/23 - 10 Days
iceman77
01/06/22​
5.5/B
2/15​
24600​
Yesin Stock!2/15/2023 - 0 Days!
JJohnMY 226.5/V
1/24​
7000​
Yes
1/24/2023​
2/13/2023​
2/17/2023 - 24 Days
TXpowerboost2022 model5.5'
1/4​
6990​
Yes
1/9/2023​
3/3/2023 - 53 Days
FLPB
01/12/22​
5.5/W
2/21​
8300​
Yes(to dealer on 27th)3/9/2023 - 16 Days
Mosey Repair #2
09/01/21​
5.5​
2/27​
17461​
Yes
3/8/2023​
3/8/2023​
3/8/2023 - 9 Days
Recurve
12/15/21​
5.5​
3/8​
8686​
Yes3/20/2023 - 12 daysSwapped O rings, not exchanger
--------------------------------------------------------------------------
Puddle
01/09/22​
5.5/W
6/20​
2000 kmNo6/23/22?
cheeser 9712MY 215.5/WFeb 2022
15468​
Yes
911spyderMY 225.5/W
7/5​
S14SuspenseLate 20215.5/W
2/12​
20000​
Yes
MtborbF-150MY 225.5/W
17000​
Watercloud6
01/12/22​
6.5ft
2/27​
10000​
No
2/27/2023​


Original part# (dependent on bed size) ML3Z-5A212-S.

The updated part for a 5.5 foot bed is NL3Z-5A212-B. - Changed with Iceman77 on 2/15/23
The updated part for a 6.5 foot bed is NL3Z-5A212-C.

For any new records get me the info in a column like so :

Forum Name
Blend (build date of your truck)
bed length/part letter
told dealer date
mileage when leak noticed
drivable y/n
part ordered date
part arrived date
installed date
any issues after

Example:
TN Rotty
12/19/22
6.5/V
03/01/22
1100
Yes
3/7/2022

If you have no info for a field, no worries - just put ??? or similar for that item
 

cpf150

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Good news for out of warranty people like myself. Parts came in and I wanted to try a self install before paying shop rates. You can do the entire repair without removing anything from the truck besides the old parts; no need to take down the section of exhaust. It's awkward but the hardest part is working upside down in a small space and removing the two lock screws. No idea on proper torque of the lock screws but I went snug, not tight because I certainly did not want to crack the exchanger body.

You need a T25 star bit to remove the lock screws that hold each tube to the exchanger body. Then remove the hose from the old tube, twist slightly (maybe 30 degrees) and remove old tube. Twist in the replacement tube and reattach hose; verify snap lock fitting on end of hose locks properly. Replace lock screw.
**Do not drop a lock screw into the metal tray/skid plate thingy or into the open exchanger hole unless you want this to be a much longer task**

Before beginning: Look under your hood and become familiar with the creme/gray colored snap fitting that Ford uses on the end of the coolant system hoses. There is one where the coolant hose goes into some component of the hybrid system just behind the coolant tank to the left and another near it slightly under the air intake tube. You twist the creme/gray colored part and then the hose just slides off. I didn't unhook these hoses from their tubes but just twisted the clamps to figure them out and could tell that they hoses would slide off if pulled. You will need to do the same thing under your truck where the hoses attach to the two angled tubes you are replacing. I did the procedure with the truck cold and put a thumb over the hose end and didn't lose hardly any coolant; not nearly as messy as I was expecting.

Pic attached shows the lock screw by each tube where it attaches to the exchanger body and the weird creme/gray twisting hose clamp things on the end of each hose. Stick your camera up in there and take a video to best understand the orientation.
Enjoy!
Ford F-150 Powerboost CEL P237C/Exhaust Heat Exchanger Leak Megathread IMG_8999
 

qewrtyturdy

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My dealer told me it’s safe to drive with this issue, is that true?
 
 




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