TSB's

Leaky EGR plumbing

Some 2011 Ford F-Super Duty vehicles equipped with a 6.7L diesel engine may exhibit an exhaust leak at the EGR inlet pipe flex joint possibly accompanied by DTC P0299 or P132B.

This concern is caused by a crack in the flex joint which typically results from a loose fastener between the pipe support bracket and the EGR cooler. Exhaust leaks may cause either of these DTCs. In addition, leaks can result in higher under hood temperatures and may lead to potential damage of the EGR bypass vacuum actuator, EGR bypass vacuum line, RH windshield washer hose, washer nozzle or engine air induction duct.

  1. With the engine off, inspect the EGR inlet pipe for soot deposits in and around the braided mesh at the flex joint. If soot deposits are present, proceed to Step 3. If no soot is found, proceed to Step 2.
  2. Using EngineEar JSP06608-D or equivalent, and with the engine running, listen for an audible exhaust leak at the EGR inlet pipe flex joint and/or sealing gasket areas. If a leak is evident, proceed to Step 3.
  3. Replace the EGR valve inlet tube. Remove the six bolts and the EGR valve inlet tube. Discard the two EGR valve inlet tube gaskets, the EGR inlet tube and the single bracket fastener. Install a new EGR inlet pipe and gaskets, tube support bracket and six bolts. Reuse five bolts and install one new fastener (location A in photo). Tighten two bolts at the EGR inlet pipe to exhaust manifold to 88 in-lb. Tighten two bolts at the EGR inlet pipe to the EGR valve housing to 88 in-lb. Apply Motorcraft Threadlock 262 to the pipe bracket fastener threads. Torque the bolt to 88 in-lb, plus 45 degrees. Tighten the bracket to inlet pipe bolt to 88 in-lb plus 45 degrees.
  4. Inspect the following areas for possible damage due to exhaust gas exposure: RH washer hose, washer nozzle, EGR bypass vacuum actuator, EGR bypass vacuum line and engine air inlet duct and repair as necessary.

PART NUMBER                                     PART NAME

BC3Z-9E469-A………………………….Tube, EGR inlet

BC3Z-9D476-D………………………….Gasket

BC3Z-9V443-A…………………………..EGR bypass actuator

W503279-S437……………………..…..Bolt (photo, location A)

TA-26……………………….…………….Motorcraft Threadlocker 262

BC3Z-9E464-E…………………………Gasket

Replace this bracket bolt.
<p>Replace this bracket bolt.</p>

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