3.0L/6.7L – Illuminated MIL With Various Reductant System Related DTCs – 2016-2022 Ford F-150 F-Super Duty

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NHTSA ID Number: 10236685

Manufacturer Communication Number: TSB 23-2161

Summary

Some 2018-2021 F-150 vehicles equipped with a 3.0L diesel engine, 2016-2022 F-650/F-750 vehicles equipped with a 6.7L engine, and 2017-2022 F-Super Duty vehicles equipped with a 6.7L engine and built on or before 08-Mar-2022 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. This may also be due to movement of the wiring harness causing terminal fretting. To correct the condition, follow the Service Procedure to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant tank, as well as securing the wiring harness using a cable zip tie fastener.

 


This bulletin supersedes 22-2191. Reason for update: Revised Part List

Model:

Ford

2018-2021 F-150

Engine: 3.0L
2017-2022 F-Super Duty
Engine: 6.7L
Built on or before 08-Mar-2022
2016-2022 F-650/F-750
Engine: 6.7L

 

Summary

This article supersedes TSB 22-2191 to update the Part List.

 

Issue: Some 2018-2021 F-150 vehicles equipped with a 3.0L diesel engine, 2016-2022 F-650/F-750 vehicles equipped with a 6.7L engine, and 2017-2022 F-Super Duty vehicles equipped with a 6.7L engine and built on or before 08-Mar-2022 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. This may also be due to movement of the wiring harness causing terminal fretting. To correct the condition, follow the Service Procedure to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant tank, as well as securing the wiring harness using a cable zip tie fastener.

Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:

 

Parts

Service Part Number Quantity Description Unit of Issue Piece Quantity Note
4L3Z-9276-AA 3.0L/6.7L - Illuminated MIL With Various Reductant System Related DTCs - 2016-2022 Ford F-150 F-Super Duty | small light 1 Sealing Pump To Tank Gasket 1 1
KC3Z-5J250-A 1 Inboard Frame Mounted Reductant Tank (F-Super Duty Pickup) 1 1
HC3Z-14407-A 1 Inboard Frame Mounted Reductant Tank Harness (F-Super Duty Pickup) 1 1
KC3Z-5J250-B 1 Outboard Frame Mounted Reductant Tank (F-Super Duty Chassis Cab) 1 1
HC3Z-14407-B 1 Outboard Frame Mounted Reductant Tank Harness (F-Super Duty Chassis Cab) 1 1
JL3Z-5J250-A 1 Reductant Tank (F-150) 1 1
JL3Z-14407-AA 1 Reductant Tank Harness (F-150) 1 1
FC4Z-5J250-H 1 Reductant Tank (F-650/F-750) 1 1
FC4Z-14407-C 1 Reductant Tank Harness (F-650/F-750) 1 1
HC3Z-5J229-B 1 Reductant Tank Pump/Heater Assembly (All Vehicles) 1 1
W520804-S439 1 Reductant Tank Retaining J-nut (F-Super Duty) 4 1 F-Super Duty requires 2 different J-nut part numbers
W719567-S439 1 Reductant Tank Retaining J-nut (F-Super Duty) 4 2 F-Super Duty requires 2 different J-nut part numbers
W503300-S450 1 Reductant Tank Retaining Strap Bolts (F-650/F-750) 4 4
W520803-S439 1 Reductant Tank Retaining Strap J-nuts (F-650/F-750) 4 4
TMRCL6 1 Natural Cable Tie, 6 In. 40 Lb – Or Equivalent No Thicker Than 1.2 mm (0.047 in.) 100 1 Rotunda Technician Tools Program part number

 

Parts

Parts To Inspect And Replace Only If Necessary

Service Part Number Quantity Description Unit of Issue
W716694-S300 If Needed Lower Reductant Tank Cover Access Door Retainer (F-Super Duty, F-150) 4
PM-27-GAL 3.0L/6.7L - Illuminated MIL With Various Reductant System Related DTCs - 2016-2022 Ford F-150 F-Super Duty | small light If Needed Diesel Exhaust Fluid (Only If The Reductant Tank Is Replaced) 1 Gallon
PM-27-JUG 3.0L/6.7L - Illuminated MIL With Various Reductant System Related DTCs - 2016-2022 Ford F-150 F-Super Duty | small light If Needed Diesel Exhaust Fluid (Only If The Reductant Tank Is Replaced) 2.5 Gallons

Quantity refers to the amount of the service part number required to repair the vehicle.

Unit of Issue refers to the number of individual pieces included in a service part number package.

Piece Quantity refers to the total number of individual pieces required to repair the vehicle.

As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as non-whole numbers, including less than 1.

If Needed indicates the part is not mandatory.

 

Service Procedure

NOTE: For DTCs P21DD, P20BA, P20B9, P204C, P208A, P208B, P208C this can indicate a concern with connector C3613. For DTCs P21CD, P203B, P205B and/or U02A2 this can indicate a concern with connector C4851 (F-Super Duty) or connector C3610 (F-150, F-650/F-750).

1. Disconnect and inspect C3613 (16 pin connector) at the reductant pump/heater assembly and C4851/C3610 (4 pin connector) at the reductant level sensor/quality module for signs of corrosion. Refer to the Workshop Manual (WSM), Section 303-08 and the Wiring Diagram.

(1). Inspect both the harness side and component side of both connectors for signs of water intrusion. Focus on all pins at connector C3613 and pins 1 and 4 at connector C4851/C3610. Inspect for signs of:

• Visible green corrosion on multiple terminals on the harness side of connector C3613. (Figure 1)

Figure 1

 

• Corroded pins on the reductant pump/heater assembly at connector C3613. (Figure 2)

Figure 2

 

• Visible green corrosion on the reductant level sensor/quality module side of connector C4851/C3610. (Figure 3)

Figure 3

 

• Visible green corrosion on the harness side of connector C4851/C3610. (Figure 4)

Figure 4

 

2. Follow the appropriate procedure:

(1). If no signs of corrosion or water intrusion are present on either connector or component, replace the reductant tank harness only.

(2). If signs of corrosion or discoloration are present on the reductant tank harness connector C3613 or reductant pump/heater assembly perform the following:

• If there is corrosion or discoloration on the reductant tank harness connector only and not on the reductant pump/heater assembly, only replace the reductant tank harness.

• If there are signs of corrosion or discoloration on the reductant pump/heater assembly, replace both the reductant tank harness and the reductant pump/heater assembly. Refer to WSM, Section 303-08.

(3). If signs of corrosion or discoloration are present on the reductant tank harness connector C4851/C3610 or the reductant level sensor/quality module perform the following:

• If there is corrosion or discoloration on the reductant tank harness connector only and not the reductant level sensor/quality module, only replace the reductant tank harness.

• If there are signs of corrosion or discoloration on the reductant level sensor/quality module, replace both the reductant tank harness and the reductant tank (reductant level sensor/quality module built in).

NOTE: Do not add any dielectric grease to the electrical connectors.

3. Prior to installing the reductant tank, using a 40lb tensile strength cable zip tie fastener, secure the harness to the reductant pump metal lock ring. (Figures 5-7)

Figure 5

 

Figure 6

 

Figure 7

 

 


50 Affected Products

Vehicles

MAKE MODEL YEAR
FORD F-150 2018-2021
FORD F-250 SD 2017-2022
FORD F-350 SD 2017-2022
FORD F-450 SD 2017-2022
FORD F-550 SD 2017-2022
FORD F-600 SD 2020-2022
FORD F-650 2016-2017, 2021
FORD F-650 SD 2017-2022
FORD F-750 2016-2018, 2021
FORD F-750 SD 2017-2022

 


1 Associated Document

Manufacturer Communications

23-2161
22 May 2023

https://www.nhtsa.gov/recalls?nhtsaId=10236685

MC-10236685-0001.pdf 797.793KB

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NHTSA ID Number: 10212102

Manufacturer Communication Number: TSB 22-2191

Summary

Some 2018-2021 F-150 vehicles equipped with a 3.0L diesel engine, 2016-2022 F-650/F-750 vehicles equipped with a 6.7L engine, and 2017-2022 F-Super Duty vehicles equipped with a 6.7L engine and built on or before 08-Mar-2022 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. This may also be due to movement of the wiring harness causing terminal fretting. To correct the condition, follow the Service Procedure to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant tank, as well as securing the wiring harness using a cable zip tie fastener.

 

1 Associated Document

Manufacturer Communications

22-2191
16 May 2022

https://www.nhtsa.gov/recalls?nhtsaId=10212102

MC-10212102-0001.pdf 300.815KB

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NHTSA ID Number: 10201907

Manufacturer Communication Number: TSB 21-2336

Summary

Some 2018-2020 F-150 vehicles built on or before 1-Apr-2020 equipped with a 3.0L diesel engine, 2017-2019 F-Super Duty vehicles built on or before 30-Oct-2019 equipped with a 6.7L engine and 2016-2019 F-650/F-750 vehicles built on or before 30-Oct-2019 equipped with a 6.7L engine may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P20BA. P20B9, P204C, P208A, P208B, P208C, P203B, P205B, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851/C3610 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. To correct the condition, follow the Service Procedure steps to replace the reductant tank harness, the reductant pump/heater assembly and/or the reductant tank.

1 Associated Document

Manufacturer Communications

21-2336
27 September 2021

https://www.nhtsa.gov/recalls?nhtsaId=10201907

MC-10201907-0001.pdf 178.783KB

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NHTSA ID Number: 10167191

Manufacturer Communication Number: TSB 19-2315

Summary

Some 2017-2019 F-Super Duty vehicles built on or before 1-Aug-2018 equipped with a 6.7L engine may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble codes (DTCs) P21DD, P204C, P21CD and/or U02A2 in the powertrain control module (PCM). This may be due to water intrusion within connectors C3613 and/or C4851 on the reductant harness going to the reductant pump/heater assembly and the reductant level sensor/quality module. To correct the condition, follow the Service Procedure steps to replace the reductant harness, the reductant pump/heater assembly and/or the reductant tank.

 

1 Associated Document

Manufacturer Communications

19-2315
18 October 2019

https://www.nhtsa.gov/recalls?nhtsaId=10167191

MC-10167191-0001.pdf 310.987KB

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