I had the newest flash installed last week, CEL was back on within 2 hours. Brought it back in yesterday, dealership spoke with Ford and was told the NOx sensors that were put in the trucks are faulty, so they are re-manufacturing them, they are on back order until the end of June.
I'm guessing those of you that had the sensors replaced then had to have some type of recalibration done, that was just a "band aid" fix for a poorly designed sensor. Also was told this is the cause for my truck not using any DEF over the past 5000 miles and going into "limp" mode when pulling heavy loads.
Hope nobody needs an inspection done on their truck before the end of June, because a dealership can't Pass it with the CEL on...

 

In one of my posts I questioned whether or not Ford had a quality issue with the sensor. Based on what you are saying, they are. I am not surprised by the timeline either. This is the model year end. They are trying to balance new vehicle manufacturing with their service part demands. If the supplier can't keep with the extra demand, delays will happen.

In my line of work, a downed product gets the part BEFORE another new one is built. I know there are at least a couple of Ford techs who are on this forum who can confirm this. I know vloney was able to locate a number of them when SGT93 was looking for one. If it is a quality issue, they would have pulled them from inventories.

 

I agree, downed product gets the fix first.. but the trucks are not disabled.. they have an annoying light. and may or may not be producing more NOx than planned. the difficulty is there is only one light to indicate discovered issues.

now, if this were an engine, tranny or suspension part that disabled the vehicle it would be a whole different thing.

and as a member of a large corporation that produces hardware products, I've been thru vendor and part qualification, receivables testing and verification, and statistical sampling of new supply over a long production run. you cannot test every single part, the costs go crazy. But, using a statistical sampling methodology opens a window of risk and quality escapes..
I think this happened here..

sam

 

I'm not sure about other owners, but my truck is disabled by this. Not for daily driving, but when pulling heavy loads the truck loses a lot of power, and goes into what they call "limp" mode, causing you to pull over, shut off the truck and restart in order to regain full power.

 

thx.. I hadn't heard this side effect. seems unlikely that the NOx sensor is the real cause (to me technically), but you never know.

the dealer should be fighting to get one of the newly manufacturered sensors as hard as they can. If he understands the actual impact of the problem on you.

Sam

 

I wonder if this means all NOx sensors are bad parts or just some?
I never had an issue because the coldest it was here this winter was 8 degrees F one morning.

I can understand how a faulty NOx sensor would limit the truck when the software programs in the modules are the deciding factor.
If the computers determine the truck isn't up to the EPA's qualifications that Ford programmed, then it would limit the trucks abilities or prevent use all together due to the reports it receives or doesn't receive from the faulty sensor.
When towing the temps are up higher so at some point the computer modules decide enough is enough and some sort of action is taken.
That's just my take on the issue.

 

Thanks for the info. It cetainly makes sense and explains why most are having the CEL come back after the latest flash. It also shows that it isn't simple incompetence by the techs loading the latest flash - as has been claimed on this board.

That whole arguement didn't hold any water logically, but the sensors still being faulty helps explain the recurring CEL. Thanks.

 

I think Sam is right about the testing aspect. Often manufacturers don't test individual parts but rather through "lots". If they did individual testing, I would expect the parts to carry a significantly higher cost.

I believe this will become a much bigger issue as vtboy points out. In my state, this truck will not pass inspection with a CEL on. And since these trucks are entering their first full year, that is happening now.

 

as I understand it, the CEL doesn't come back on immediately..

so have the dealer clear the code, then do the inspection..
altho a waiver from the manufacturer should fix that too. Chevy had to get that kind of exemption as well.

sam

 

When my dealer searched for the NOX part it showed through Ford that it was being replaced and the current version was not in stock (or something to that effect). Through the help of Vloney, a Ford "God" I must say ( minor butt kiss) he found some sensors in Memphis along with 2 o3 NOX boxes. Told my dealer and they ordered the parts and placed them in my rig. The tech went for a test drive and BAM....CEL back on. My tech spoke with Ford ont he phone for further solutions and they did some sort of an airbox recalibration. My tech drove the truck for two days after that and to this day....CEL FREE! Are the parts faulty...probably. Will mine come back on...maybe. If there is a new sensor in production there is good reason. I want it ready if mine comes back on. I have a feeling it will when the temps begin to change to the white stuff again. The techs can fix them but they need to be willing to go above and beyond to get it done. Duane at Shields Auto in Rantoul IL did just that and I am thankful. I hope you all get them fixed soon as it is annoying for sure. I know I felt loss of power of a few occasions and towing regularly that would have drove me nuts. Especially for you guys that tow for a living. There is hope out there, just find the mech that will do it. Maybe your mech can call Duane at Shields Auto (he is the only Ford diesel tech) for assistance?

 

Could there be a connection to build date? Mine is a 6-10-10 build date and I haven't had any CEL issues. Knocking on wood as we speak. What are your build dates?

 

I took delivery around 7/14/10, and have had the CEL on since February, reset twice and back on. I'm not convinced it's cold weather related since it came back on with temps in the 70's. Unless the cold weather is causing the sensor to go bad, resulting in it comging back on even during summer months.

 

Pretty sure there was a bad batch of sensors in the late summer builds b

 

Mine is a May 2010 build and I have the CEL issue so who knows.

 

It appears some CELs turn back on within a few miles.
If an owner must drive 30+ miles to the DMV for inspection, that CEL will probably be back on by the time they arrive.
I've noticed some owners don't even have a dealership near them so it's an hour or more drive.
I guess Ford is nearing the GM mess with this issue.
Either the dealers will handle the inspection or Ford will need to figure something out quickly.

My knowledge related to vehicle inspections is limited to what I read here, though.
We don't have such a thing in AL.
Are there fines involved if you have a CEL?