Runs Rough During Exhaust Regeneration Process - 2011-2016 Ford F-250, F-350, F-450

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NHTSA ID Number: 10090502

Manufacturer Communication Number: TSB 16-0136

Summary

SOME 2011-2016 F-SUPER DUTY PICKUP VEHICLES BUILT ON OR BEFORE 23-FEB-2016 AND EQUIPPED WITH A 6.7L DIESEL ENGINE MAY EXHIBIT A RUNS ROUGH/MISFIRE CONDITION ONLY DURING THE EXHAUST REGENERATION PROCESS. THIS CONDITION TYPICALLY OCCURS ON LIGHT THROTTLE TIP IN BETWEEN 64-113 KM/H (40-70 MPH) AND WILL NOT SET DIAGNOSTIC TROUBLE CODES (DTCS). THE CONCERN MAY BE INTERMITTENT AND A KNOCKING NOISE MAY BE PRESENT DURING THE CONCERN. FOLLOW THE SERVICE PROCEDURE STEPS TO CORRECT THE CONDITION.

FORD:

2011-2016 F-250, F-350, F-450

This article supersedes TSBs 16-0041 and 15-0124 to consolidate information and update the Service Procedure.

ISSUE:

Some 2011-2016 F-Super Duty 250-450 Pickup vehicles equipped with a 6.7L diesel engine and built on or before 23-Feb-2016 may exhibit a runs rough/misfire condition only during the exhaust regeneration process. This condition typically occurs on light throttle tip in between 64-113 Km/h (40-70 MPH) and will not set diagnostic trouble codes (DTCs). The concern may be intermittent and a knocking noise may be present during the concern.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Reprogram the powertrain control module (PCM) to the latest calibration using Integrated Diagnostic System (IDS) release 102.03 or higher. Make sure you are connected to the internet when entering module programming to obtain the latest updates. Calibration files may also be obtained at www.motorcraftservice.com.
Did the customer indicate the message center displayed a Cleaning Exhaust Filter message prior to the concern?
1. Yes – proceed to Step 3.
2. No – proceed to Step 6.
Remove the left cylinder head. Refer to Workshop Manual (WSM), Section 303-01.
Replace all eight (8) exhaust valves and valve seals. Refer to WSM, Section 303-01. (Figure 1)

Figure 1

Install the left cylinder head. Refer to WSM, Section 303-01.
Provide the customer with a copy of the attached customer information sheet. (Figure 2)

Genuine Manifold Gasket (SOLD AS A PACKAGE OF 2) BC3Z-9439-C

Figure 1

36 Affected Products

Vehicles

MAKE	MODEL	YEAR

FORD	F-250 SD	2011-2016
FORD	F-350 SD	2011-2016
FORD	F-450 SD	2011-2016
FORD	F-550 SD	2011-2016
FORD	F-650 SD	2011-2016
FORD	F-750 SD	2011-2016

NHTSA ID Number: 10205006

Manufacturer Communication Number: TSB160041

Summary

Pickup – 6.7L Diesel Engine – Runs rough during exhaust regeneration process – built on or before 02/23/2016

1 Associated Document

Manufacturer Communications

TSB 16-0041

https://www.nhtsa.gov/recalls?nhtsaId=10205006

MC-10205006-9999.pdf 317.789KB

⬇ Download PDF (310.34 KB)

NHTSA ID Number: 10074710

Manufacturer Communication Number: TSB-15-0124

Summary

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

1 Associated Document

Service Bulletin Document

TSB-15-0124

https://www.nhtsa.gov/recalls?nhtsaId=10074710

SB-10074710-7690.pdf 801.74KB

⬇ Download PDF (782.95 KB)

Reprogramming

Service Information & Reprogramming

Module Reprogramming

Diagnostic Software	Interface Device	Complete Vehicle Diagnostics		Module Programming
Diagnostic Software	Interface Device	1996-2017 Model Year	2018-Present Model Year	1996-2017 Model Year	2018-Present Model Year
IDS/FDRS	VCM, VCM II, VCMM	X	X	X	X
FJDS/FDRS	Compatible J2534 Devices (Including VCM II and VCMM)		X	X	X

Detailed system requirements, installation, and support information for each product is located under the diagnostics tool support tab for each product.

Integrated Diagnostic Software (IDS) / Ford Diagnosis & Repair System (FDRS)

For use with VCM I, VCM II, VMM and VCMM hardware devices only. The complete factory Ford Motor Company vehicle diagnostic tool that provides complete dealership level vehicle diagnostic coverage for all 1996 to present Ford, Lincoln and Mercury vehicles. The IDS software includes time based access to the IDS software, software updates and calibration files.

Ford J2534 Diagnostic Software (FJDS) / Ford Diagnosis & Repair System (FDRS)

For use with compatible J2534 hardware devices. FJDS software provides Ford Module Programming functionality that covers 1996 to present Ford, Lincoln and Mercury module reprogramming functions, plus complete dealership level vehicle diagnostic software for all 2018 to present Ford and Lincoln vehicles. The FJDS software license includes time based access to the FJDS software, software updates and calibration files.

Latest Calibration Information

Module Build Data (As-Built)

Use VIN to obtain As-Built data

www.motorcraftservice.com

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PART NUMBER	PART NAME
BC3Z-9439-C Genuine Manifold Gasket (SOLD AS A PACKAGE OF 2) BC3Z-9439-C Geniune OEM part $19.78 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-10 / Affiliate links / Images from Amazon Product Advertising API	Upper Intake Gasket
BC3Z-9439-A Ford Gasket - Intake Geniune OEM part $24.28 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Upper Intake Gasket – (Inlet Large)
BC3Z-9439-B Ford Gasket - Intake Geniune OEM part $14.47 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Upper Intake Gasket – (Inlet Small)
BC3Z-6N640-A Ford BC3Z-6N640-A, Exhaust Pipe to Manifold Gasket Year: 2011 2012 2013 2014 2015 2016 2017 2018 2019, Other Part Number: BC3Z-6N640-A, Custom Bundle: No Manufacturer Part Number: BC3Z6N640A, Manufacturer Warranty: 1 Year, Modified Item: No Returns Accepted: Returns Accepted, Model: Compatible with F-250 F-350 Super Duty, Warranty: 1 Year Oe/Oem Part Number: BC3Z6N640A, Non-Domestic Product: No, Part Brand: Compatible with Ford $8.04 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-09 / Affiliate links / Images from Amazon Product Advertising API	Turbo Inlet Gasket Left Hand
W711402-S900 Ford W711402-S900 - Nut Adjust Screw Genuine OEM Part: Authentic Ford W711402-S900 nut adjust screw designed specifically for Ford vehicles, ensuring compatibility and reliable performance with your vehicle's adjustment mechanisms Precision Engineering: Manufactured to exact Ford specifications with tight tolerances to provide smooth and accurate screw adjustment functionality for optimal mechanical operation Durable Construction: Built with high-quality materials that resist wear, corrosion, and thread stripping, ensuring long-lasting performance even under demanding automotive conditions Direct Replacement: Designed as an exact fit replacement for worn or damaged adjustment nuts, making installation straightforward without requiring modifications or additional adapters Essential Hardware Component: Critical fastening element that maintains proper tension and adjustment in various automotive systems, helping to preserve the integrity of your vehicle's mechanical assemblies $14.99 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Exhaust Manifold Nut
BC3Z-8287-A Ford CLAMP Geniune OEM part $26.95 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Inlet Pipe Clamp (2 Req)
BC3Z-6587-A Ford Gasket - BC3Z6587A Item Package Dimension: 5.00L x 2.00W x 1.00H inches Item Package Weight - 2.00 Pounds Item Package Quantity - 1 Product Type - GASKETS Gasket $18.73 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Turbo Gasket
W713535-S900	Bolts
BC3Z-8287-B Ford CLAMP Geniune OEM part $17.25 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Down Pipe Clamp
BC3Z-9E464-B No products found.	Bypass Pipe Gasket
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BC3Z-6A632-A Ford Gasket - Plate Geniune OEM part $4.91 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Oil Separator Gasket
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W701706-S440 Dorman 03414B Exhaust Manifold Hardware Kit Compatible with Select Models Direct replacement - this exhaust manifold hardware kit matches the original hardware required to secure the exhaust manifold to the engine on specified vehicles Ideal solution - this kit is a reliable replacement for the original hardware that is missing or damaged, or has failed Durable construction - this kit is made from quality components to ensure reliable performance and a long service life Trustworthy quality - backed by team of product experts in the United States and more than a century of automotive experience Ensure fit - Input your vehicle into the garage tool and check Confirmed Fit bar at the top of the page. If there is an “i” in a blue circle, additional verification is needed. Please hover over the "i" to verify fitment notes match your vehicle. $24.92 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Nut (8 Req)
BC3Z-8C387-B Ford Gasket Geniune OEM part $18.88 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Right Side Coolant Manifold Gasket
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BC3Z-8527-N Ford BC3Z-8527-N - Ring Sealing Genuine Ford part that fits your specific vehicle Engine Coolant Pipe O-Ring Part Number: BC3Z8527N Manufactured to meet specifications for fit, form, and function $24.17 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Heater Tube O-Ring
BC3Z-6065-B Ford BC3Z-6065-B, Engine Cylinder Head Bolt Model: Compatible with F-250 Super Duty F-350 Super Duty, Type: Engine Cylinder Compatible with Head Bolt, Make: Compatible with Ford Manufacturer Part Number: BC3Z-6065-B, Placement On Vehicle: Engine Material: M12 X 175MM Compatible with Hex Head Bolt, Certification: Compatible with Genuine OEM Fitment Type: Direct Replacement, Warranty: 1 Year $7.63 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Cylinder Head Bolts
F7DZ-6A008-AA Ford F7DZ-6A008-AA - PIN Genuine Ford part that fits your specific vehicle Pin Part Number: F7DZ-6A008-AA Manufactured to meet specifications for fit, form, and function $11.92 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Cylinder Head Dowels
DC3Z-6051-F Genuine Ford Parts - Gasket - Cylinder Head (DC3Z-6051-E) OEM Ford Parts Genuine Ford Parts Manufactured To Ford Standards Genuine Ford Parts And Accessories Not After Market Parts Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-09 / Affiliate links / Images from Amazon Product Advertising API	Cylinder Head Gasket
BC3Z-6571-A Ford BC3Z-6571-A, Engine Valve Stem Oil Seal Genuine Ford part that fits your specific vehicle Engine Valve Stem Oil Seal Part Number: BC3Z6571A Manufactured to meet specifications for fit, form, and function $10.43 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API	Valve Seal
CC3Z-6505-B Genuine Ford Parts - Valve - Exhaust (CC3Z-6505-B) OEM Ford Parts Genuine Ford Parts Manufactured To Ford Standards Genuine Ford Parts And Accessories Not After Market Parts Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API	Exhaust Valve (8 Req)
BC3Z-6584-C Ford Gasket - Valve Geniune OEM part $51.99 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API	Left Side Valve Cover Gasket
BC3Z-6C535-A	Injector to Valve Cover Seal (4 Req)
BC3Z-9E964-A 1 Reviews Ford BC3Z-9E964-A - PIPE - FUEL Genuine Ford Part BC3Z-9E964-A Engineered by Ford specifically for your vehicle Ford quality construction Warrantied by Ford Motor Company Customer will be contacted if core charge applies to part. $309.98 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-18 / Affiliate links / Images from Amazon Product Advertising API	Fuel Rail Supply Tube
BC3Z-8527-D	Fuel Supply O-rings
BC3Z-8527-E	Fuel Supply O-rings
BC3Z-9229-A Genuine Fuel Injector O-Ring Kit BC3Z-9229-E Genuine Ford OEM product $69.08 Buy on Amazon Price incl. tax, excl. shipping Last update on 2026-06-10 / Affiliate links / Images from Amazon Product Advertising API	Injector Seal Kit (2 Req)
BC3Z-9229-B No products found.	Injector Seal Kit (2 Req)
BC3Z-9E464-B No products found.	EGR Outlet Gasket (2 Req)
W714852-S900 No products found.	EGR Outlet Tube Bolt (4 Req)

Runs Rough during Exhaust Regeneration Process – 2011-2016 Ford F-250, F-350, F-450

Summary

SERVICE PROCEDURE

Summary

Summary

Reprogramming

Service Information & Reprogramming

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