2009 F250 FX4 Crew Cab 5.4L, 6Spd, 62,750miles

My truck recently had issues with the catalytic converter. Upon the issue starting I did some searching here but really didn't find a lot of solutions. The solution I did find was the extended warranty letter that was sent out in 2010 explaining that the catalytic converter in 2008-2010 gas powered super duty may fail and the warranty is now 11 yrs or 120,000 miles (I saved my letter in my truck file). However, many of the cases I found for bad cats in the forum for this model year truck resulted in the owner having to pay for the repair. So in an attempt to make sure others know about the issue and don't have to pay, I wanted to post my symptoms and outcome.

Issue started as a rattle in the passenger catalytic converter upon cold start. Once the exhaust warmed up, it went away. The issues progressed over about a week. My truck sits a lot since I have a company car, but within one week I was calling a tow truck. The last night I drove the truck I began to experience a loss of power and louder exhaust and check enegine light. After eating dinner with the family on the drive home I experienced severe loss of power, missfires in the same bank as the converter rattling and eventually total loss of power to where I couldn't exceed 2nd gear and about 15 mph. Upon delivery of the truck to the dealer and explaining the situtation and showing them the letter, all was resolved. But as I said in the begining, it looks a lot of owners have paid for this repair. Hopefully this will help other in the future.

 

Mine did the same thing. Severe rattling when cold only, by the time i got to dealer it went away so had to leave it there overnight so they could cold start it. Mine happpend at 34k so i was still on warrenty. Thanks for lettinng us know about the extension! If mine go again im just cutting em out

 

2008 V-10. Just had my converters replaced about 2 weeks ago under this extended warranty. The y-pipe with both converters is what is replaced. Symptoms were the converter rattling when cold and eventually a check engine light. The code set was P0430. Never had driveability problems.

 

How many miles are on your truck?

 

Only 37,000.

 

I was hoping that this would be the case for me and my 2008 E350 V10. When I called my dealer they said I'm not covered by any extension. Do you have any documentation on this extension that you can share? Or a link to where it can be found?

 

Thanks for the posting and I'm also interested in the extended warranty on the cats. I think I hear a slight rattle when I start my 2010. Documentation from Ford would be great to have in case I need to make a claim. My truck has about 67k on it now.

 

If your vehicle was included in this program (it's not a recall), your VIN will be loaded into OASIS already. Your dealer can check for applicability.

The program covered "certain" F250 and F350 trucks assembled only at the Louisville plant between a certain range of days (you'd have to read the dealer's version of the information). If you don't have an F250 or F350 that was assembled at Louisville between the effective days, your truck is automatically excluded from that particular program.

 

Mine went out at about 30,000. Same symptoms extreme noise when cold for about 5 minutes. I recorded it on my cell and played it for dealer so i didnt have to play the "cant duplicate problem" game. Replaced under standard warranty.

 

QUOTE=BGLeRoy;15319973]I was hoping that this would be the case for me and my 2008 E350 V10. When I called my dealer they said I'm not covered by any extension. Do you have any documentation on this extension that you can share? Or a link to where it can be found?[/QUOTE]

I found this and unfortunately it doesn't apply to your E350.



Customer Satisfaction Program 10M05 - Catalyst Y-Pipe Warranty Extension In some of the affected vehicles, certain vehicle operating conditions can cause the catalyst substrate to crack or melt. This can cause symptoms including but not limited to audible noise from the catalyst y-pipe and/or malfunction indicator lamp illumination. If an affected vehicle experiences the failures identified above, dealers are to install an improved catalyst ypipe and reprogram the Powertrain Control Module (PCM). This program extends the coverage of the catalyst y-pipe to 11 years of service from the warranty start date of the vehicle or 120,000 miles, whichever occurs first. If a vehicle has already exceeded the mileage limit, this coverage will last through March 31, 2011. Coverage is automatically transferred to subsequent owners. This service will be performed at no charge to the vehicle owner. (This program covers certain 2008 through 2010 model year F250 and F-350 vehicles equipped with a 5.4L or 6.8L gas engines.)

 

I have an '08 and received the same notices for the "y" pipe and convertors. After about 80,000 mile my y pipe started leaking and the dealer replaced it with no questions asked and no cost to me, but I did have to leave the truck overnight. The dealer also told me that when the convertors go bad a lot of times the customer will complain of rattling noises in them. I did have occaisional rattling but never a drivability problem, I just brought in to have it checked and they found a leak. It helps to have a good relationship with a service advisor at your local dealer.

 

My 250 has no codes but the dealer said both converters need replaced, $1100, is this possible

 

Sorry to be such a noob, but what is OASIS?

 

Online Automotive ServiceInformation System

Ford's proprietary vehicle and service database used by their dealer network.

 

I hope it's not tied into their PATS programming system. I think carrier pigeons carry the code back and forth. 2 hours and then some....I know you can pgm them if you have 2, but I rarely get 2 keys with a used car/truck, so I at least needed a spare, and got one for the wife's chain as well, since the $125 labor pain, I mean charge, didn't go up for the 2nd one.