NHTSA Complaint #11719515 — 2019 FORD F-150

My 2019 Ford F-150 (2.7L EcoBoost) is subject to Emission Recall 24E12, which addresses a defective PCM calibration that Ford acknowledges "could, over time, reduce the effectiveness of the emissions control system and the monitoring accuracy of the catalytic converter's efficiency." COMPONENT: Catalytic converter system and powertrain control module (PCM). Vehicle is available for inspection at Rich Ford in Albuquerque, NM, where it has been serviced for this issue. TIMELINE: Prior to the 24E12 recall repair, my truck had intermittent P0420/P0430 codes (catalyst efficiency below threshold). The check engine light would illuminate and then clear on its own. I brought the vehicle to Rich Ford for the 24E12 PCM reprogram. Within approximately one month of the recall repair, the same catalytic converter codes returned, except now the condition is constant and no longer clears. This timeline is documented in my FordPass app and the dealer's service records. SAFETY RISK: The constant check engine light prevents the vehicle from passing Bernalillo County emissions testing, which is required for registration in Albuquerque, NM. I am unable to legally register my vehicle due to a condition caused by a manufacturer-acknowledged defect. DEALER CONFIRMATION: Rich Ford diagnosed the recurring P0420/P0430 codes. They initially attempted to charge me $300+ for extended diagnostics. They are now consulting with Ford about whether a catalytic converter replacement will be covered under the recall. PRIOR SYMPTOMS: The intermittent check engine light with P0420/P0430 codes existed before the recall repair but was not constant. The recall repair worsened the condition from intermittent to persistent. PATTERN: Ford's recall documentation states the MIL "may illuminate even though a catalytic converter repair may not be necessary," yet numerous owners report being quoted $1,900-$2,100+ for cat replacement at their own expense after the 24E12 reprogram. Ford corporate confirmed the $300