P2457 on Ford: How to Diagnose & Fix
Exhaust Gas Recirculation Cooling System Performance
1 Ford model · 1 documented issue · 1 critical · $800-$3,500 repair
P2457 on Ford by model: symptoms, diagnosis and fix
The EGR (Exhaust Gas Recirculation) cooler on 2011-2019 6.7L Power Stroke diesel engines is prone to clogging with soot and eventually failing, particularly on trucks used for highway driving, light loads, or trucks that idle extensively. The EGR cooler recirculates cooled exhaust gas back into the intake to reduce NOx emissions. Over time, soot accumulates in the cooler's internal passages and restricts exhaust gas flow through the cooler core, and a cooler that overheats can fail. When it fails, exhaust gases enter the coolant system, causing overheating and "puking" coolant from the degas bottle. The 2011-2014 models are particularly susceptible due to narrow internal coolant passages. Ford TSB 13-6-5 (superseding 12-6-14) covers 2011-2012 6.7L trucks with DTC P0401 and P2457, calling for EGR cooler core replacement under normal New Vehicle Limited Warranty coverage. The EGR cooler for 2011-2016 is OEM part BC3Z-9V425-A; 2017+ is HC3Z-9V425.
Common Symptoms
- Coolant loss with no visible external leak
- Coolant reservoir overflows or "pukes" coolant
- White smoke from exhaust (coolant in combustion)
- Engine overheating warning
- DTC codes P0401 (Insufficient EGR Flow) or P2457 (EGR Cooler Performance)
- Bubbling or foaming in coolant degas bottle
- Loss of power under load (especially towing)
- White deposits around degas bottle cap
How to Fix
Replace EGR cooler (BC3Z-9V425-A for 2011-2016; HC3Z-9V425 for 2017+). For 2011-2012 trucks with DTC P0401 (Insufficient EGR Flow) and P2457 (EGR Cooler Performance), Ford TSB 13-6-5 applies; coverage follows the truck's normal warranty, so have a Ford dealer check the VIN. Preventive: use a fuel additive (Diesel Kleen, Hot Shots Secret EDT) to reduce soot. Perform regular EGR cleaning at 60,000-mile intervals. Upgrade kits from Sinister Diesel and Dorman (904-405 kit) include both EGR cooler and gaskets.
Sources for this issue (2)
P2457 code reference
General diagnostic-code context. The code alone does not confirm a cause for your vehicle; use the applicable issue card and its sources.
Frequently asked questions
What does P2457 mean on a Ford?
P2457 stands for "Exhaust Gas Recirculation Cooling System Performance." Generic code set when the PCM determines the EGR cooler/cooling system is not lowering recirculated exhaust gas temperature as much as expected — the cooler is underperforming, often due to clogging, coolant flow loss, or a stuck bypass. On Ford it is documented across 1 model: F-250 Super Duty.
What are the most common causes of P2457?
The most common causes of P2457 are: Carbon-clogged/restricted EGR cooler, Loss of coolant flow through the cooler, Stuck EGR cooler bypass valve, Faulty temperature sensors used for the monitor. The specific cause varies by vehicle.
How much does it cost to fix P2457 on a Ford?
Published repair estimates on Ford range from $800 to $3,500 depending on the model and root cause. If an issue mentions a recall or campaign, check your VIN with the manufacturer or NHTSA and confirm eligibility and coverage with a dealer.
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Content compiled with AI assistance using NHTSA complaints, TSBs, and owner reports. May contain errors. Always verify with your vehicle's service manual.