Gas Recirculation Valve (egr Valve) problems of the 2018 Ford F-150

After Ford performed a pcm (powertrain control module) reprogramming recall on 16 July 2025, the vehicle began experiencing repeated engine misfires, loss of power, and engine warning lights. The condition progressively worsened, leading to a leaking fuel injector, an egr valve that stuck open, and eventual internal engine damage requiring full engine replacement. These failures involve pcm-controlled systems (ignition timing, fuel injection, and exhaust gas recirculation) and occurred shortly after the recall calibration. The issue has been confirmed and documented by an authorized Ford dealer. The truck has become unsafe to drive due to stalling and shuddering at highway speeds, which could pose a risk of loss of vehicle control. Warning lamps and a wrench icon appeared intermittently before the engine shuttering and loss of power. The vehicle and all repair documentation are available for inspection upon request.

The contact owns a 2018 Ford F-150. The contact stated while driving approximately 20 mph, there was poor power and the check engine warning light illuminated. The vehicle was driven to the dealer and diagnosed with a powertrain control failure. Additionally, the cooling system was not operating effectively. The egr bypass valve was replaced. The contact stated that the failure was related to manufacturer recall campaign: 20e04. The manufacturer was notified of the failure. The approximate failure mileage was 30,000.

Driving about 30mph down a rural street and I started to lightly apply brakes as I was coming to a corner. The truck lost all power and the engine shut off. No power steering nor power brakes. A message appeared in the cluster display saying � autostart shift to p and restart engine�. I had to pull the truck over to a side street narrowly missing a semi truck that was coming down the street(because it was difficult to turn and stop the vehicle since the power assist was no longer working). I had to completely stop the truck, place shifter into park position and restart it. It worked fine after this. The vehicle had been started about 3 minutes prior to the event. It was 54 degrees and engine had not completely warmed up yet.

I purchased it brand new in October 2018, doors would randomly fly open when cornering. I brought it in there was a recall it was fixed. Then when it is below 30 degrees my rear sensor drivers side would show a steady red and beep when there was no danger. The dealer told me that there is most likely moisture in the sensor but would not replace it. Then at 41,000 miles my engine blew a rod. They told me I was not changing oil frequently enough. I change my own oil. I provided receipts for oil but they would not warranty it, I paid $15,000 out of pocket to have a new engine installed. I called Ford corporate and after four months of investigating they had the dealer refund my money. Then at 43,000 miles I was on vacation and the sunroof would not close. I brought it to a local dealer who said there might be something in the track but they would need the truck for 4 days and I was leaving the next day. I brought it to my local dealer upon return and they charged me $4,300 to replace the entire panoramic roof rails and chassis. Most recently my 10 speed transmission was shifting very hard and in the weeks following that a check engine light came on. I called another local dealer because I had lost all confidence in the dealer I purchased the truck new from. They told me that the wiring harness for the transmission was not properly secured and chafing caused it to run through and cause false and intermittent signals. They told me because it was negligence on the dealer who replaced the engine. I would have to go after them for the $800 fix. The same dealer who replaced the harness called me later that week while waiting for the part, told me that it was now the trans valve core. They replaced it and it is has not changed anything. They are currently waiting on direction from Ford. I have been in a loaner or rental for well over 90 days cummulativley. Unnacceptable!.