NHTSA Complaint #11664638 — 2018 FORD F-150

Background: I’ve had my F150 for 7 years. For 6.x years though, the truck was operating with improper software in the Powertrain Control Module (PCM) that managed the Emissions system’s control and monitoring. This is according to the Ford Recall Notice in Feb 2025 (2E14) stating the above. To address the Recall, a Ford technician came to my house, performed the software recall update, and immediately afterwards, my check engine light came on. Days later, back at the Ford dealer, they charged me a $200 diagnostic fee, and concluded my Catalytic Converter was bad and needed replacement. And the $2000 repair would be my responsibility since my mileage was (now) over the Emissions Warranty limit. My question to them was: “when did the Catalytic Converter fail”? Dealer answer: Not sure. The old/incorrect software couldn’t detect when it went bad. My comment: So the Converter may have failed in year 1 ,2, 3, 4 or 5 (still in warranty term) and just not flagged it back then? Dealer Answer: It’s possible, no way to know for sure. Point is: There’s a good chance the part actually ‘failed’ during the warranty period. How can Ford logically assign responsibility to me when the software was ‘incorrect’ for 6 years?? I DON'T LIKE DRIVING A TRUCK THAT'S POLLUTING MORE due to a failed Catalytic Converter, but the dealer wasn’t able to explain why it failed AFTER the warranty period. I feel that Ford should replace the Converter at their cost since the point of failure was most likely during warranty, but never triggered due to the defective/recalled software that the Truck had for it's entire life. There are online people saying similar. Got the recall done, then was told they needed a $2000 repair to the Converter. I suppose many will just continue to drive with the non functioning catalytic converter.