6.4L Powerstroke – P0128, P0196, P1335, P0404, P0406, P246C, P2463

6.4L – VEHICLES BUILT BETWEEN 1/3/2008 AND 9/15/2008 – DTCS P0128, P0196, P1335, P0404, P0406, P246C AND P2463

ISSUE

Some 2008 F-Super Duty 250-550 vehicles equipped with a 6.4L diesel engines and built between 1/3/2008 and 9/15/2008 may require a calibration update which will cover several different concerns.

ACTION

Follow the Service Procedure steps to correct the condition.

NORMAL OPERATING CHARACTERISTICS EXHAUST SYSTEM REGENERATION

This document provides additional information on the conditions of normal operation while the vehicle is in the exhaust filter regeneration process. These are normal conditions and do not require repair. For most driving conditions, normal exhaust filter regeneration will begin anywhere from 100-600 miles (161-966 km) from the completion of the last regeneration cycle. Each occurrence will last from 10-40 minutes.

The exhaust filter regeneration process will not initiate or may be terminated when:

• The vehicle is stopped at idle for more than 5 minutes in gear.
• The vehicle is operated in Power Take Off (PTO) mode.
• Stationary Elevated Idle Control (SEIC) is engaged.
• The gear selector is placed in Park or Neutral.

Vehicle characteristics change during the exhaust filter regeneration process:

• Some white smoke in cold ambient temperatures is normal. The amount of white smoke during this time will be increased during exhaust filter regeneration.
• The engine’s peak power is modestly limited during regeneration.
• Engine responsiveness may be slightly different than normal operation during regeneration.
• Exhaust smell may be noticed during the exhaust filter regeneration process – especially on new vehicles.
• The powertrain sound will be different during exhaust filter regeneration including air induction noise, combustion noise, flutter on deceleration or shut down.

SERVICE PROCEDURE

Reprogram the Powertrain Control Module (PCM) to the latest calibration before performing diagnostics and clear all diagnostic trouble codes (DTCs) after programming. For DTC’s generated after reprogramming, follow normal diagnostic service procedures.

Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release 61.19 and higher or 62.07 and higher. When reprogramming the PCM on automatic transmission equipped vehicles the Transmission Control Module (TCM) will also automatically be reprogrammed to the latest level. This new calibration is not included in the VCM 2009.7 DVD. Calibration files may also be obtained at www.motorcraft.com.

Please print out the customer information sheet attached to this TSB and insert into the glove box with the Owners Guide for future customer reference.

Calibration Update Includes:

1. Diesel Particulate Filter (DPF) regeneration will not initiate at idle or in power take off (PTO) mode. When Drive To Clean Exhaust Filter is displayed in the message center, PTO and/or stationary elevated idle control (SEIC) must be disengaged / inactive in order to properly clean the DPF. The vehicle must be driven until the Cleaning Exhaust Filter message is extinguished.
2. Diagnostic and malfunction indicator lamp (MIL) operation improvements for DTCs P0128, P0196, P2002, P006B, P2563, P0108, P0234, P1260, U0073, P042E, P042F, P0404, P1335, P041C, P2457 and P2263 set during key on engine running (KOER) self test.
3. Calibration improvements for DTCs P246C and P2463 only apply to PTO equipped vehicles and vehicles that utilize SEIC.
4. Improved cold start driveability for vehicles operated in temperatures below 32°F (0°C).
5. Revised Pressure Control Valve (PCV) / Volume Control Valve (VCV) learning tables for vehicles that exhibit DTCs P0087 and/or P2291 following replacement of the High Pressure Pump or major fuel system repairs. Reset the PCV/VCV learning tables and fuel injector parameters with IDS using the clear Fuel Injector parameters.
6. Enhancements for vehicles that exhibit white smoke during diesel particulate filter (DPF) regeneration at ambient temperatures below 55°F (13°C).
7. Improvements to reduce P0544, P2031, P242A, P242B, P2080, P2084 and P117B set on long decelerations after cold start.
8. Resolution for vehicles that exhibit a no crank condition, Failure Mode Effects Management (FMEM) continuous timer count down due to Exhaust Gas Temperature Sensor disconnect while performing system diagnostics or vehicle battery disconnect.
9. IDS tool updates for DPF manual regeneration diagnostic testing referenced in Powertrain Controls/Emissions Diagnosis (PC/ED) Pinpoint Test RB.

This calibration also includes the following instrument cluster (IC) message center display updates: Drive To Clean Exhaust Filter, Cleaning Exhaust Filter and Exhaust Filter Drive Complete. Please see the Customer Information Sheet for additional information.

WARRANTY INFORMATION

WARRANTY STATUS:  Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.