I realize there have been several threads on this issue. Please humor me.
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I have two questions. Today my dealer re-flashed my F250’s PCM based on TSB 12-06-05. First, has this re-flash solved the problem for others? Second, can anyone recommend a good OBD II code reader/scanner which will allow me to reset the fault if it comes back and thereby restore normal operation for a time? I really don’t want to be stranded in “limp mode” or idle mode” several hundred miles from home.
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A bit of history. I purchased my 2012 F250 in September this year. At 1230 miles I got an “exhaust fluid system fault” message with a “speed limited to 50 mph in 50 miles” warning. A system check showed the DEF level as “OK”. There were no prior messages relating to DEF usage, low DEF levels etc. I called the dealer, who told me to bring it in. The message/warning cleared itself prior to my reaching the dealership. The service writer told me no code would be stored since the message/warning had cleared, and added approximately 2 gallons of DEF to the DEF tank. He offered to keep the truck and put me in a loaner so that they could test drive the truck. We discussed the fact that this seemed to be an intermittent problem which might not recur for some time and I elected to keep the truck.
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At 2287 miles the “exhaust fluid system fault” message came back on accompanied by a “speed limited to 50 mph at restart” warning. Again the system check showed the DEF level as “OK”. Again, no other DEF related messages, and the tank had been filled about 1000 miles earlier at the dealer. I was relatively close to home so I elected to shut the truck off and restart to see if the warning was true. It was. I then went to Wally World, and picked up a 2.5 gal container of “Blue DEF”. I added approximately 2/3<SUP>rd</SUP> to 3/4<SUP>th</SUP> of a gallon of DEF to the tank, and when I restarted the truck the message/warning had reset and operation was normal.
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The next day (today) I contacted the dealership and described the problem. I also noted that this problem had been documented on various forums and seemed to have multiple causes. The service writer had me bring the truck in and they pulled the codes he originally had told me wouldn’t be stored and decided to re-flash the PCM based on TSB 12-06-05.
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Thanks,
Jack

 

Jack:

Welcome to FTE. Great group of people here.

bruce...

 

Welcome to FTE, Jack.

Sometimes the codes these new vehicles will drive you insane.

Hopefully the flash fixes the issue. Others have had success with the flash. It gets frustrating while the service guys go thru the learning curve. There are a lot of knowledgable folks here. Let us know if your problem stays away.

 

"Let us know if your problem stays away."

Ron, thanks for the welcome. I'll try to update, but it took nearly 30 days and slightly over 1000 miles for the problem to recur.

My frustration shades toward the "dark side" when I consider some of the implications of this problem. IMHO this is a poorly conceived, badly designed system. I understand that the EPA doesn't want the diesel emissions and that they suspect some, perhaps many, would simply ignore the empty DEF tank if the system didn't include the (relatively) gradual shut down of the vehicle. The problem is the arrogance in believing they could construct a system that would not breakdown and strand a vehicle. There are places in this country (the bureaucrats and pols call it flyover country) where being in "limp mode" and restricted to 50 mph will put you 30 - 40 mph (or more) slower than the other traffic, to say nothing of being reduced to idle. There is simply no justification for building those defaults into the system to "encourage" folks to keep the DEF tank full. Sooner or later Murphy will be unable to resist the temptation to step up to the plate and some poor sole will find himself stranded in a bad place.

 

I had the same problem and re flash. 1k miles and no trouble but if this **** keeps up Ford is gonna wish they never heard from me. This is a safety issue.

 

My biggest fear is what it would cost to maintain these trucks when the warranty runs out. I agree with you about the being stranded thing or placed in a precarious situation because of an electrical component failure. GM had some real problems with their DEF system when they launched and were granted a variance from EPA a couple years ago. I assume they must have solved their problems. I haven't followed up on them.

 

While frustrating, Ford isn't the only one who has their share of DEF issues.
Ford also didn't have to get a pass from the government to bypass certain emission systems either.
While GM eventually corrected that issue, that problem was much worse.

Dodge is joining this ball game for the first time with their 2013 model year whereas Ford and GM already have two years of real-world troubleshooting under their belt.
Dodge owners are going to be reporting similar issues, just wait.