About 3 weeks ago, I started having a variety of warnings and alert lights on my 17 SD F350. Alerts started with "reduced power" and then moved to "50 MPH limit in xx miles". Checked DEF and it was full. (that should have been the first "huh", because I've driven about 10k since last fill). Cleared OBD. Still getting engine light, and message said "DEF Heater low voltage. Didn't worry too much, because plenty warm.
Other lights progressively showed up, including Service ATS and DPF Plugged. Weird combinations. Only one time did the truck actually get reduced top speed to 50, but more and more times getting DPF warnings.

Last week took to Ford dealer to diagnose. They said that DEF Pump, module, and cable needed to be replaced. I bought parts and replaced them yesterday.

When I pulled the pump, I was SHOCKED. The pump uses rubber covered sensors for fluid level, and a bunch more rubber covered "zig-zag" wires at the top portion of the pump. They look like heater wires. Anyway, see the photos of the shocking revelation. The wires/sensors were coming out of the rubber float/covers. This 2017 truck has only 54k miles on it!

The problem looks like a manufacturing defect (poor choice of rubber material). The material was not corroded or melted looking, but ever peice was cut opened by the metallic strips or wires.
Of course, Ford refuses to cover due to 54k v 50 k warranty limit.

Wondering if anyone else has seen this particular defect?

BTW, truck ran fine afterwards. No more DEF or ATS warnings, but still have DPF Plugged after 80 mile highway speed drive. Today going to try to force regen.

Thanks!

Longest of the 3 level guage "flaps". Notice metallic strip exposed.

Tears in the rubber on top of pump. Wires are present (though hard to see in this photo. Notice the bumpy characteristics of the upper right side.

Good shot of the zig-zag wires in the top orange rubber.

 

wouldn't this emissions system failure be covered by the 8/80k emissions warranty?
what a mess

 

Heavy duty vehicles (8500 gvwr and up) get a 5yr/50k mi emissions warranty.

 

All those rubber tendrils are the heater elements, not for DEF level.

But, it is strange that they are torn like that.

 

Hey 4WD6.7L, thanks for the response. I am fairly certain that the elongated flaps are level monitors. There are 3 of them, and the metal strip appears to be a bi-metallic strip that will vary resistance based on the level to which it rises. One is for low levels, one for moderate, and the long one for a full tank. That said, I have no proof of that.

I really thought that the stuff that appears to be stuffed in the top of the pump (with zig-zag wires) is a multi-element heater, but I don't understand why there would be heaters on the pump and a separate heater 6 inches away from the pump? Curious.

Still haven't been able to get the PDF to clear the filter. Drove it for about 3 hours today in 4th or 5th gear to keep RPM above 2500 (mostly 3000). Still says it is plugged and my OBDAutoDoctor software doesn't appear to want to perform a manual regen for reasons that are not at all clear to me.

Thanks again.