Documented F-150 PowerBoost Problems and Coverage, 2021–2023
Table of Contents
What Ford has actually documented on PowerBoost trucks
Ford has documented a short list of F-150 PowerBoost problems in writing: cracked coolant spigots on the exhaust heat exchanger, check engine light codes tied to its valve, a catalyst-efficiency code, and two 2025 hybrid recalls.
This page sticks to what Ford’s own documents name for the hybrid, checked against Ford and NHTSA records on October 1, 2026.
Find your situation: coolant dropping, a warning light, a quote in hand, or a high-mileage truck. Each is answered below by model year. For other engines and years, see F-150 problems by year, matched to documented Ford coverage.
ℹ️ Safety Note: Hybrid high-voltage systems, hot exhaust parts, and engine cooling are safety-critical. This page explains what Ford documented, not how to repair anything. Have warnings or coolant loss inspected by a qualified technician before continuing to drive.
Which PowerBoost model years each document covers
Ford scoped each PowerBoost document by model year and build date, and the ranges differ.
2021–2023: bulletins and programs
| Document | Applies To | Covers |
|---|---|---|
| SSM 51103, SSM 51485 | 2021–2022 built by 18-Apr-2022; 2021–2023 | Cracked coolant spigots |
| SSM 52050 | 2021–2023 built by 01-Mar-2023 | Codes P237C, P2C22, P2C23 |
| CSP 24N04 | 2021–2023 built 10-Jan-2020 to 8-Sep-2023 | Heat exchanger actuator |
| CSP 25M04 | 2021–2023 built 10-Nov-2020 to 6-Sep-2023, by VIN | Spigot cracks |
| Recall 24E04 | 2022–2023 built 15-Sep-2021 to 16-Nov-2023 | Software, catalytic converters |
Sources: Ford service bulletins and dealer programs as filed with NHTSA; status checked October 1, 2026.
2024–2025: what is and isn’t documented
Recalls 25S29 (47 trucks, built 30-Jan to 5-Feb-2025) and 25C31 (56,473 trucks, built 22-May-2024 to 26-Jun-2025) are 2025 hybrids only. Our research found no hybrid-specific bulletin or recall for 2024. Lightning and Maverick recalls don’t apply.
Coolant loss and check engine lights on a PowerBoost
Ford describes two separate exhaust heat exchanger failures on 2021–2023 PowerBoost trucks.
Cracked coolant spigots
SSM 51485 says the coolant spigots on top of the heat exchanger can crack, leaking engine coolant and risking overheating or a check engine light.
🔍 Why It Happens: Ford calls the part an exhaust gas heat recovery system. Its coolant spigots connect it to the engine cooling system, so a crack lets coolant out.
Valve and actuator codes
SSM 52050 links a light with P237C, P2C22 or P2C23 to the bypass control valve. CSP 24N04 adds P237D, P237E and P237F and blames water reaching the actuator’s circuit board; it applies only when those codes are stored.
Ford’s bulletins in order, from SSM 51103 to CSP 25M04
Customer Satisfaction Program 24N04 is Ford’s no-cost, one-time repair for a failed exhaust gas heat recovery system on certain 2021–2023 F-150 hybrids.
Service bulletins
SSM 51103, SSM 51485 and SSM 52050 tell dealers how to repair; they don’t set coverage terms.
Customer satisfaction programs
Programs set coverage terms. CSP 25M04 (December 2025) follows the earlier 25N05 for spigot cracks, and says a weaker spigot used in an earlier repair can crack again. The approved replacement carries a gold marking.
📋 On the Record: 24N04 Supplement #1, dated December 2, 2024: 15 years or 150,000 miles from warranty start, one-time, transferable to later owners, applicable only with matching stored codes. Status checked October 1, 2026.
Is your PowerBoost still covered? Terms, dates and recalls
Coverage turns mostly on mileage. Ford’s programs run 15 years or 150,000 miles from warranty start, and a truck built in 2020 or later reaches 15 years in 2035 at the earliest.
Dates passed and coming
For trucks past those limits, 24N04 ran through March 31, 2026; we found no extension, so ask a dealer. The 25M04 spigot repair runs through March 31, 2027, and afterward Ford says a service-part warranty or extended plan may cover repairs. Emissions recall 24E04 doesn’t expire.
Open recalls on 2025 hybrids
Recall 25S29 covers 47 trucks with a wrong high-voltage fuse. Recall 25C31 covers 56,473 trucks that may miss a seat-belt chime. Check your VIN with the Recall & VIN Lookup Helper. Ford’s hybrid-unique component coverage lasts 8 years or 100,000 miles; heat exchanger eligibility is unconfirmed.
What PowerBoost repairs take, in Ford’s labor hours
Ford’s published labor hours help you sanity-check a quote.
💵 On these numbers: These are Ford’s dealer warranty allowances, not retail prices. Parts, shop rates, and region change real quotes.
Heat exchanger repairs
Ford allows 0.8 hours for the 24N04 actuator repair, including coolant top-off and alignment, and 0.5 hours to replace the spigot pair under 25M04.
Catalyst codes P0420 and P0430
TSB 25-2233 covers these codes on 2022–2023 PowerBoost trucks with a software update. Ford allows up to 3.1 hours for diagnosis, plus 3.0 if the right catalyst is replaced, 0.8 for the left, or 3.2 for both.
💵 What It Costs: Multiply the hours by your shop’s quoted rate, then add parts; question quotes far above that. Repair Cost Estimator can help.
What to do about a coolant leak or hybrid warning
A dropping coolant level or a new warning deserves a prompt inspection, not panic.
Coolant loss or overheating
Ford’s bulletin lists overheating as a possible result, so have coolant loss inspected by a qualified technician soon.
Hybrid or drive-power warnings
Ford’s report for recall 25S29 says a wrong fuse can cause sudden loss of motive power in electric-only mode; a “Stop Safely Now” message displays when the fuse faults. It applies to 47 trucks built January 30 to February 5, 2025.
✅ Do This: Ask the shop to print your stored codes and run your VIN for 24N04, 25M04, 24E04, 25S29 and 25C31. Ask whether replacement spigots carry Ford’s gold marking.
PowerBoost problems FAQ
1. Is the PowerBoost heat exchanger covered?
Ford’s CSP 24N04 and 25M04 cover heat exchanger repairs on listed 2021–2023 trucks within 15 years or 150,000 miles; a dealer confirms eligibility by VIN.
2. What is CSP 24N04?
It is Ford’s no-cost, one-time repair for a failed exhaust gas heat recovery system on certain 2021–2023 F-150 hybrids built through September 8, 2023.
3. Does 24N04 expire?
For trucks past 15 years or 150,000 miles, 24N04 coverage ended March 31, 2026; we found no extension, so ask a dealer.
4. Which years does the spigot program cover?
CSP 25M04 covers listed 2021–2023 PowerBoost trucks built from November 10, 2020 through September 6, 2023, identified by VIN in Ford’s system.
5. Is there a recall on the F-150 hybrid?
Ford has an emissions recall, 24E04, for 2022–2023 trucks and two 2025 hybrid recalls, 25S29 and 25C31. Check your VIN for open recalls.
6. How long is the hybrid component warranty?
Ford covers hybrid-unique components for 8 years or 100,000 miles; whether the heat exchanger qualifies is unconfirmed.
7. What does P237C relate to in Ford’s bulletin?
SSM 52050 says a check engine light with P237C, P2C22 or P2C23 may stem from the exhaust heat exchanger bypass control valve.
8. Do 2024 PowerBoost trucks have the heat exchanger problem?
Our research found no hybrid-specific Ford bulletin or recall for model year 2024; Ford’s heat exchanger documents cover 2021–2023 builds only.
9. How many labor hours is the 24N04 repair?
Ford allows 0.8 hours for the F-150 24N04 actuator repair, including coolant top-off and alignment; shop quotes and parts cost vary.
10. What should I ask my dealer?
Ask for stored codes printed and a VIN check for 24N04, 25M04, 24E04, 25S29 and 25C31, plus whether new spigots are gold-marked.
Your next step
Run your VIN for open Ford programs and recalls, then bring a printed list of stored codes to the dealer. If a quote arrives, compare its labor hours with Ford’s figures above, and ask which program applies to your truck’s model year and build date. This page reflects Ford documents checked on October 1, 2026; programs and recall status can change.
