Warning FORD 6.7L STOP SAFELY NOW EGT sensor malfunction
 

These trucks have 4 EGT sensors on the exhaust system that are failing between 50,000 and 70,000 miles. (48,600 in my case AND out of town!)
When they fail and they do so without any warning, YOU ARE DEAD IN THE WATER!!!
The truck will start to shift down until you reach a creep speed (under 4mph) and then completely shut off.
You usually can't start it again without the Ford dealer overriding the system and clearing a code. I was able to restart after about 2 hours sitting in traffic at a stop sign.
Even so it will happen again and again until the affected sensor is replaced. The sensors are about $60 apiece and the labor is about $300. Or under 30 mins if you carry a spare

If you have 50,000'ish miles on your truck, I highly reccommend that you get to the Ford dealer for sensor replacements.
You'll probably have to pay for it as the warranty may not cover the repair, but you will avoid getting left high and dry & paying for a tow.

They issued a recall on them BUT ONLY ON AMBULANCES.
Online option is Ford is likely to get a lawsuit over this once someone gets into a bad accident because of this failure and forced shutdown in a dangerous situation as it cannot be overridden to "limp in". It's a forced shutdown when a sensor fails without warning.

You have been warned! Do some online searches for more info, but mine failed again & had to get towed in.
I for one will be carrying spares from now on because it was a total day wrecker while out of town hunting with my girls over the weekend.

What year is your truck? This should be covered under the 100K Diesel warranty.

I am fairly active on powerstroke.org and haven't heard about this problem as being a widespread issue. I have a 2011 F-350 with over 80K on it and 'knock on wood' nothing like this has happened.

Are all the EGT sensors the same part numbers?

Thanks for passing this information along.

I have a 2013...24k miles...so I'm curious as he!! too!

Here's another instance where someone got stranded because of the DPF system. Going into "idle only" mode at the wrong time seems like it would definitely cause some problems on the freeway.

https://www.youtube.com/watch?v=Qu16sPNgR00

Gotta love it waiting for the ambulance and it dies on the road , I say again can O worms .:(

ya know...I have been around diesel engines my entire life being in the business I'm in...the time has passed when I could fix the problem myself (troubleshoot, pull and replace parts)...it's off to the shop or call the tow truck to come pick it up....and that includes the heavy equipment I have too...call the dealer at $125 an hour plus travel time, mileage, fuel surcharge, environmental fee, consumables etc!!! man who here owns a dealership, you should be able to own a d@mn fleet of powerboats LOL.

there are several things with those things that if the ECM does not like it...you are walking !!!! heard of it happening numerous times..

Yup Not a good deal, happened to our 2012 f350. None of our dealers stock the part and ford had it on back order. Lost a week with our equipment delivery truck being down.

Sounds like a 86 Chevy Crew Cab w/502 aftermarket FI(and possibly whipple), along a Turbo 400 and Gear Vendors Over/Under drive may be the ticket.

Even with low mpg and stould still end up being way cheaper than today's deisel trucks considering for the got damn repairs.

Damn new truck world sucks ...especially for those who work out of them.

Never had the issue with my 11 F250 however my brother in-laws 12 F250 has had them go out several times. He was told its caused by excessive idling ( deal claim).

I had 3 of the 6.7s now only 2 and have had this happen multiple times. None of the trucks have over 30k miles on them. Simple fix according to local ford dealer. "Just put a bunch more highway miles on them and you won't have this problem." I said f u and I am cutting off all exhaust filter crap as soon as warranty is up. And they blow fuses to trailers all the time. All 3 of mine, my dad's f450 and my buddies f350 blew the same fuses. I still love the trucks though.

I got told the same thing when I had my 2011. My drive to and from work is only 12 or 13 miles so it would rarely kick into regen or wouldn't complete regen and ended up going into limp mode on me a couple of times.

Now I've got a 5.9 Cummins and don't have to deal with the def/dpf/egr bs. But, all in all the 6.7 power stroke is a nice truck.

Man, ford just dove head first into a diesel hole from hell and cant climb out.... Back in the early 90's I had a ford 6.9 boxvan for racing and you couldnt kill that thing if you had to. They dont make em like that anymore.

2012 f250 with 49k, but i dont think lack of idling will get me. I commute into New Orleans daily for a 80 mile round trip. No issues yet..

i have a 2011 f350 with 22,500 miles,no problems....yet.

We've got a dozen of these newer ford's at work. F550 crew cabs. Apparently they've had their share of problems from what I've heard. The trucks they are phasing out of the fleet with these, are older F350 crew cabs, with V10's. The older V10 trucks, have served them well, very reliable, according to the mechanics. These trucks spend most of the day idling, or simply getting beat on by the drivers. The older V10 trucks mostly have 80-130k miles on them, but tons of hours. Supposedly the purchasing dept is rethinking the diesel powered pickups after the recent purchase of these newer fords for this kind of use.

2011 80K no problem. Lots of short trips. I am listening. 0 defects.

11 F450 100,000 miles now... no problem with EGT... but Rad started leaking just out of warranty... few other small things but the truck has been good overall
lots of idling... now that I posted this somethings going to happen to it.... LOL

Truck is way way too complicated under the hood........fans/radiators/sensors everywhere!

My 03 Duramax was bone stock and went 170K miles. Here was the total repair list:
1. 106K miles, water pump
2. 132K miles, one front wheel bearing (I changed both and did front brake pads while it was apart)
3. 155K miles, injectors covered under GM extended warranty (zero cost to me)
4. 165K miles, pulley failed, needed to be towed/new pulley and belt
5. 200K (I traded it, new owner told me he had only done a gauge cluster (used off ebay $25)

Did 2 sets of batteries and 3 sets of tires in my ownership but I would consider those wear items not repairs.

Now maybe I had good luck or got a good truck off the line but this would be my expectation owning a new 50-60K pickup......certainly not the nonsense listed above. BTW not a Ford hater, I traded the GMC for a new Ford back in 2011.

I would say that the radiator issues on the 6.7 is widespread problem. Issues like these I feel fall into the "$hit happens" catagory. But like Jupiter Sunsation said these new trucks have wires and sensors all over the place and if on of those components fail it will make for a bad day. I will take a sensor failing over a turbo, injector or internal component failing any day of the week. Now, I hope like hell I just didn't jinx myself because the Ford dealerships in Houston are not good at all!!

I have a F550 with a 6.7 with 175k and no issues other than a a/c compressor. Also have a f350 with the 6.7 that has 45k on it with no issues. I did the delete kit on the 350 and it's the best thing I ever did!

I also love my Ford truck, BTW it's a 2012 F-250.
Before we bought it I test drove a new Dodge Mega Cab and the Ford side by side, one of the local dealers carries both brands. I jumped out of one and right into the other, then asked the salesman, "how much less is the Dodge" when he said they're the same price it made my decision easy and I've been loving it every single day since then...until this weekend.
Now I'm not running out to trade it in, but I will be prepared next time & hopefully so will anyone else who owns one and didn't know about this wide spread problem.
It really sucks when you buy brand new vehicles under warranty because you don't want to deal with headaches then get left stranded in the middle of nowhere! I had my 10 & 12 year old girls with me hunting and non-running truck = no heat for 2 hours. Turns out if you keep an extra sensor, p/n AC3Z-5J213-B, a code scanner and a 13mm wrench you can fix it yourself pretty easily.

Read your warranty paperwork and window sticker the new 6.7 only have a 70k mile warranty on them for motor! I learned that after the fact lol

We even have the extended warranty to 100,000 miles, but it doesn't matter when you're broke down hours from home!
It's a total trip wrecker having to get towed and figure out what to do with your trailer & family.
That's why I posted this, just trying to help fellow 6.7L FORD owners be prepared for the inevitable EGT sensor fail.

Someone tried telling me all you need to do is wait 30 mins and it resets itself, but that was not the case for my situation.
I tried to wait for an hour without any key turns, that didn't work.
I even tried to unhook the batteries for 45 mins and no dice.
In fact I was on the phone calling for a tow and left the key on by accident, while talking to them the warning suddenly went away and the truck started!

I got a few blocks down the road and it popped right back up, but instead of slowing down I kept my foot in the gas and "drove through it" actually we made it all the way back home about two hours away before it happened again right down the road from the house. Then I couldn't get it re-started and called for a tow.
I think I got lucky and made it that close to home. Felt like a ticking time bomb every time I had to stop though because if it happens when stopped the truck dies!

thanks for this great info,i will be adding a sensor,wrench and my code scanner to my travel kit.

Makes you want to leave town with it again ha ha , picked the wrong make that mutha will leave you hangin again .

everything we buy now is computer controlled crap.... works good when its working but forget about trying to fix most of it yourself anymore.... In Canada factory powertrain is 160,000 kms/ 100k miles (almost) oh ford did the waterpump and driveshaft covered under warranty just before i hit the 160k

As a diesel power tuning hobbyist, I'll attempt shed a bit of light on what's happening here. All the new domestic trucks share this same part, and point of failure.

The engine goes into "limp mode" because those EGT sensors are considered part of the emissions system. Nothing to do with engine safety. If any part of "emissions" fails, or provides the ECM out of spec data, the ECM/PCM goes into limp. Forcing the driver to resolve this issue within a few miles, or push the truck home. Cause we all know it's better to limp 100 miles out of the bush, while maintaining legal emissions. Even if that means you'll likely be eaten by a bear along the way. At least you'll die with a CLEAN conscience.

On a good note, if you do make it into a dealership, push the point that these are emissions critical parts. Ask to see the fault codes, and then point out where is says EPA - Emissions beside the description. If your under 80k they "should" be covered like the DPF and other exhaust parts according to the LAW. But you may need to jump up and down and shout at the service manager with a high volume to get his attention to this fact.
Another good link on this http://www.thedieselstop.com/forums/...s-ford-448801/

Your other choices are as listed above. Carry spares sensors, a scan tool of some sorts, and learn to change them yourself. Along with something to keep the bears off you while making the change. Luckily our Aussie friends are exempt from such troubles. They successfully petitioned the government to allow one to legally remove, or at least work around these limp problems. How? By stating my 100 miles in the bush case, and swapping out the "bear" with horny-rabbit kangaroo's...

It worked for them, and some nice guys from New Zealand released a tuning system called EFIlive. For now it only works on GM and Dodge, but does allow one to "in case of dire emergencies" remove all that limp related stuff from of the ECM. Thus avoiding being ass raped by said kangaroo's, or eaten alive by a grizzly bear. With new Ford's 6.7L it's a little tricky, but professional SCT tuners can still write off-road RACE tunes that do the same thing. Saving you from the bears and kangaroo's, but allowing you to be ass raped by the feds if they catch ya running it on the street.

Hope that helps. And remember, always carry good running shoes in your new diesel vehicle...

So due to the fact that a few have had EGT sensor failures, which I don't doubt at all, we should condemn all 6.7 Fords? I appreciate feedback, and adhere to a regiment that will help alleviate failures due to poor maintenance. With that said our facilities service hundreds of 6.7 Fords. We have seen some EGT sensor failures. But in no way would it ever present me the concern to avoid the trucks. Matter of fact I have one with 30k on it and it works extremely well. The % of EGT failures to the number of the 6.7s on the road is extremely low. Of course that is of small consolation when one breaks down on the road.

Sam

Page 10 & 11 for power train and diesels.

http://www.ford.com/resources/ford/g...1&zoom=100,0,0

I have a 2011 and no where did I find a 70,000 mile warranty for a Ford truck. They have 3/36,000 for bumper to bumper, 5/60,000 for entire power train and 5/100,000 for the diesel engine.

Unless Ford changed something with the newer model year 6.7s? But I (not that "I" really matter) haven't heard or read of them doing so.

who said condemn fords????

If somebody wants to put the blame for these crappy motors on anybody, it's the federal government and the EPA. Man those guys know how to screw up a good thing, just look what they did to our gas by adding water (ethanol) to it.

2014 6.7 with 50,000 and no issues at all. Have a 02 7.3 with 450,000 and only minor repairs. Mseuro is 100 percent correct all the emission gadgets are tools to comply with the restrictions our government puts on the auto builders. Wife just showed up a Christmas present for herself a new Raptor, cool truck.

New neighbor of mine has a Roush Raptor.......that thing is loaded!

What is the delete kit? I have a 2011 350 and I was going to start looking for tuners or ecm mods to get better fuel economy assuming they exist.

I got the H&S programmer and dpf delete pipe. No more urea and egr is shut off. Great power and better mileage and the oil stays much cleaner! Sounds good too!

Drivers of 2015s are saying they still have a 100,000 miles on the diesel engine.

If you have some different warranty information please pass it along.

***

I just was told the 70,000 is for the exhaust system. Now the question is this, should the EGT probes be covered under the engine's warranty, since there failure will shut engine down? In my opinion the EGT probes are NOT a function of exhaust and are VERY much so a function of the engine since they are connected to the ECM and will shut the engine down if they fail.

[You are correct i am wrong its only a 60k mile powertrain warranty. I still have the window sticker I can show you what it says. Give me your email I will send you a pic!!!

60QUOTE=TW720HVY;4242209]Drivers of 2015s are saying they still have a 100,000 miles on the diesel engine.

If you have some different warranty information please pass it along.

Or maybe you need to find a new dealership that understands the warranty program on their diesels.[/QUOTE]

No that is alright, that is how I understand it as well.

I still believe that the EGT probes should have been covered under you engine warranty if you're still under the 5/100 mark. These are not part of the power train coverage IMO since the engine requires information from them for the normal operation. It seems as if your dealership is either trying to screw you or isn't fully aware of the warranty program.

On a side note, I took my 2011 in for a shifting problem that has a TBS out for it. I provided a description of the issue word for word that the TBS stated and when I went to pick it up I was told it wasn't covered. I was told this by three different Service Writers, but I did not accept their answers because I already knew the answer from a friend who works at another dealership. They finally took it behind a close door to the manager and came out to tell me I was right and that it was covered.

My point is this, I was outside the 60K power train window and it was a hesitation and shifting issue, but it was part of the EMC/TCM programing which is a function of the engine.