PICKUP - 6.7L DIESEL ENGINE - RUNS ROUGH DURING EXHAUST
REGENERATION PROCESS - BUILT ON OR BEFORE 2/23/2016

TSB 16-0041

FORD:
2015-2016 F-250, F-350, F-450
This article supersedes TSB 15-0106 to update the Issue Statement, Service Procedure and Part List.
ISSUE
Some 2015-2016 F-Super Duty 250-450 Pickup vehicles equipped with a 6.7L diesel engine and built on or before
2/23/2016 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
1. Reprogram the powertrain control module (PCM) to the latest calibration using Integrated Diagnostic System (IDS)
release 99.03 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
2. Did the customer indicate the message center displayed a Cleaning Exhaust Filter message prior to the concern?
a. Yes - proceed to Step 3.
b. No - proceed to Step 6.
3. Remove the left cylinder head. Refer to Workshop Manual (WSM), Section 303-01.
4. Replace all eight (8) exhaust valves and valve seals. Refer to WSM, Section 303-01. (Figure 1)

Figure 1 - Article 16-0041
5. Install the left cylinder head. Refer to WSM, Section 303-01.
6. Provide the customer with a copy of the attached customer information sheet. (Figure 2)
PART NUMBER

PART NAME

BC3Z-9439-C

Upper Intake Gasket

BC3Z-9439-A

Upper Intake Gasket - (Inlet Large)

NOTE: The information contained in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job
properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service.The
procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership
to determine whether the bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan
coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves
the right to supercede this information with updates.The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2016 Ford Motor Company

Online Publication Date March 7, 2016

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TSB 16-0041 (Continued)

PART NUMBER

PART NAME

BC3Z-9439-B

Upper Intake Gasket - (Inlet Small)

BC3Z-6N640-A

Turbo Inlet Gasket Left Hand

W711402-S900

Exhaust Manifold Nut

BC3Z-8287-A

Inlet Pipe Clamp (2 Req)

BC3Z-6587-A

Turbo Gasket

W713535-S900

Bolts

BC3Z-8287-B

Down Pipe Clamp

BC3Z-9E464-B

Bypass Pipe Gasket

BC3Z-8527-A

Oil Separator O-Ring

BC3Z-6A632-A

Oil Separator Gasket

FC3Z-9448-A

Exhaust Manifold Gasket

W701706-S440

Nut (8 Req)

BC3Z-8C387-B

RH Coolant Manifold Gasket

BC3Z-8C387-A

LH Coolant Manifold Gasket

BC3Z-8527-N

Heater Tube O-Ring

BC3Z-6065-B

Cylinder Head Bolts

F7DZ-6A008-AA

Cylinder Head Dowels

DC3Z-6051-F

Cylinder Head Gasket

BC3Z-6571-A

Valve Seal

CC3Z-6505-B

Exhaust Valve (8 Req)

BC3Z-6584-C

LH Valve Cover Gasket

BC3Z-6C535-A

Injector to Valve Cover Seal (4 Req)

BC3Z-9E964-A

Fuel Rail Supply Tube

BC3Z-8527-D

Fuel Supply O-rings

BC3Z-8527-E

Fuel Supply O-rings

BC3Z-9229-A

Injector Seal Kit (2 Req)

BC3Z-9229-B

Injector Seal Kit (2 Req)

BC3Z-9E464-B

EGR Outlet Gasket (2 Req)

W714852-S900

EGR Outlet Tube Bolt (4 Req)

OPERATION

DESCRIPTION

TIME

160041A

2015-2016 F-Super Duty 250-450 Pickup 6.7L: Reprogram The PCM (Do
Not Use With Any Other Labor Operations)

0.4 Hr.

160041B

2015-2016 F-Super Duty 250-450 Pickup 6.7L: Reprogram The PCM
And Replace Eight (8) Exhaust Valves In The Left Cylinder Head (Can
Be Claimed With Operation C OR D) (Do Not Use With Any Other Labor
Operation Outside Of This Article)

15.4 Hrs.

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TSB 16-0041 (Continued)

OPERATION

DESCRIPTION

TIME

160041C

2015-2016 F-Super Duty 250-450 Pickup 6.7L: If Required, Additional
Time To Remove And Install Fuel Shield To Access Lifting Points (Can
Be Claimed With Operation B) (Do Not Use With Any Other Labor
Operations Outside Of This Article)

0.1 Hr

160041D

2015-2016 F-Super Duty 250-450 Pickup (FX4 Model) 6.7L: If Required,
Additional Time To Remove And Install Fuel Shield To Access Lifting
Points (Can Be Claimed With Operation B) (Do Not Use With Any Other
Labor Operation Outside Of This Article)

0.3 Hr.

WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are
determined by the identified causal part and verified using the OASIS part coverage tool.
DEALER CODING
BASIC PART NO.
6505

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CONDITION CODE
42

TSB 16-0041 (Continued)

Figure 1 - Article 16-0041
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