2023 Hybrid P2C22 | P237D Heat Exchanger failure

[BostonMaverick]

Over the last week my daily trip mpg had been declining from 50+ mpg down to low 30s. On Tuesday night there was a mild shudder in the drivetrain immediately followed by the MIL turning on. I keep a scan tool in my glovebox and pulled codes P2C22 and P237D.

The service team at my dealership was fantastic to work with. I stopped by Wednesday morning without an appointment and the issue was verified in under 30 minutes. I declined a rental since I have my wife's car while she is out of town. They gave me a ride home.

The repair was completed this morning and they arranged a ride to pick me up. They even did the brake light recall while it was there. My trip MPG on the drive home was 60.

The heat exchanger failing seems to be a common issue on the hybrid. I've read several posts where people had to wait weeks or months for parts. Hopefully this quick repair is a sign that parts are more readily available for other owners with the same issue.

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[FlyGuy09]

How many miles at the time of failure?

 

[BostonMaverick]

How many miles at the time of failure?

8900

 

[KevCuRaoi]

Over the last week my daily trip mpg had been declining from 50+ mpg down to low 30s. On Tuesday night there was a mild shudder in the drivetrain immediately followed by the MIL turning on. I keep a scan tool in my glovebox and pulled codes P2C22 and P237D.

The service team at my dealership was fantastic to work with. I stopped by Wednesday morning without an appointment and the issue was verified in under 30 minutes. I declined a rental since I have my wife's car while she is out of town. They gave me a ride home.

The repair was completed this morning and they arranged a ride to pick me up. They even did the brake light recall while it was there. My trip MPG on the drive home was 60.

The heat exchanger failing seems to be a common issue on the hybrid. I've read several posts where people had to wait weeks or months for parts. Hopefully this quick repair is a sign that parts are more readily available for other owners with the same issue.

I had that code last winter on mine. I work at the dealership.... initially, the heat exchanger wasn't available separately, so you had to order the whole exhaust. That was on back order. I ordered the part for myself...but after 3 months it was still on back order. The CEL went off so I just cancelled the order.

CEL and P2C22 returned yesterday. There is now a SSM that directs the dealership what parts to order. The heat exchanger and other necessary parts are currently readily available.

 

[RedRider]

I had that code last winter on mine. I work at the dealership.... initially, the heat exchanger wasn't available separately, so you had to order the whole exhaust. That was on back order. I ordered the part for myself...but after 3 months it was still on back order. The CEL went off so I just cancelled the order.

CEL and P2C22 returned yesterday. There is now a SSM that directs the dealership what parts to order. The heat exchanger and other necessary parts are currently readily available.

This seems to be a common issue on the hybrid and probably the primary reason why anyone would consider an extended warranty. Reading even the most expensive warranty coverage, it appears to be a not-covered part. Previously the entire exhaust system was replaced as a unit, costing US$1400 plus labour, but Ford seems to have redesigned the exhaust to allow this part to be swapped out in a much cheaper way. How much is the repair?

 

[clearviewx]

Go B’s!

 

[KevCuRaoi]

This seems to be a common issue on the hybrid and probably the primary reason why anyone would consider an extended warranty. Reading even the most expensive warranty coverage, it appears to be a not-covered part. Previously the entire exhaust system was replaced as a unit, costing US$1400 plus labour, but Ford seems to have redesigned the exhaust to allow this part to be swapped out in a much cheaper way. How much is the repair?

The heat exchanger has possibly been redesigned (there has been a part # change, so something in the design or manufacturer has changed). The original part # (when this part was available seprately), shows MSRP of $1,005 USD. The current updated part # is only $353.33 USD (in Feb 2024, pricing can change monthly!). Two clamps are also needed. $79 each.

The MSRP of the whole exhaust/converter assembly is also much reduced. Currently $752. It was once $1600. This assembly is on its 3rd part number (so hopefully also an updated heat exchanger!)

My repair will be under warranty still. The labor shouldn't be much for just replacing the heat exchanger.

 

[KevCuRaoi]

This seems to be a common issue on the hybrid and probably the primary reason why anyone would consider an extended warranty. Reading even the most expensive warranty coverage, it appears to be a not-covered part. Previously the entire exhaust system was replaced as a unit, costing US$1400 plus labour, but Ford seems to have redesigned the exhaust to allow this part to be swapped out in a much cheaper way. How much is the repair?

Hmmm I did look in the parts coverage directory, and 18K463 (base number for the heat exchanger/auxiliary heater assembly) does appear to be covered on PremiumCare Ford Protect plans. But to be certain, I'd want to run it through Ford's part coverage tool. I don't have an extended warranty on mine to be able to check the coverage.

Prior to 2021 MY, this part also seems to have had some extended coverage under US Emissions warranty, but something seems to have changed starting with 2021 vehicles, and that extra coverage no longer exists.

Currently, in the US, the heat exchanger is only covered under 3/36 bumber to bumber warranty.

I'm not sure of the situation in Canada for any of these! But I do think I could check coverage using a Canadian VIN....

 

[BostonMaverick]

We added a 10 year premium care extended warranty at the time of purchase. We tend to keep our vehicles 15+ years. Will it be money wasted or money well spent? Only time will tell. Stay tuned.

 

[Guy_Montag]

The heat exchanger has possibly been redesigned (there has been a part # change, so something in the design or manufacturer has changed). The original part # (when this part was available seprately), shows MSRP of $1,005 USD. The current updated part # is only $353.33 USD (in Feb 2024, pricing can change monthly!). Two clamps are also needed. $79 each.

The MSRP of the whole exhaust/converter assembly is also much reduced. Currently $752. It was once $1600. This assembly is on its 3rd part number (so hopefully also an updated heat exchanger!)

My repair will be under warranty still. The labor shouldn't be much for just replacing the heat exchanger.

How is yours covered under warranty and others aren't?
My check engine just came on, right after getting the CV axle replaced and a couple recalls done... I'm trying earnestly to figure out what coverage I purchased because this dealership keeps telling me that can't see any service or maintenance plans on my account... but I'm certain I paid for them, just don't remember what the name of it was and am getting no help from Ford)

 

[KevCuRaoi]

How is yours covered under warranty and others aren't?
My check engine just came on, right after getting the CV axle replaced and a couple recalls done... I'm trying earnestly to figure out what coverage I purchased because this dealership keeps telling me that can't see any service or maintenance plans on my account... but I'm certain I paid for them, just don't remember what the name of it was and am getting no help from Ford)

It's covered by 3/36 bumper to bumper warranty. I've got 23K miles and less than 2 years.

Are you talking to the dealership you purchased the plans from? Or a different one?

If it is a different dealership, and you purchased an aftermarket plan, then other dealership won't be able to look anything up in Ford's system.

 

[Master Blaster]

This seems to be a common issue on the hybrid and probably the primary reason why anyone would consider an extended warranty. Reading even the most expensive warranty coverage, it appears to be a not-covered part. Previously the entire exhaust system was replaced as a unit, costing US$1400 plus labour, but Ford seems to have redesigned the exhaust to allow this part to be swapped out in a much cheaper way. How much is the repair?

The wording of the Ford warranties is really bad. They look like they were worded by someone in their legal department sometime back in the 70's. All of them result in lots of misreading , even by the dealers. They need to either step up and put in the correct wording for the covered parts clearly and simply, or remove all of that lawyer wording and just state that everything unique to hybrid drivetrains is covered. Since this heat exchanger is a hybrid-unique part, it is then obvious that it is covered for 8 years even to a recalcitrant dealer.

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