F150 ecoboost drilled my intercooler
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BandannaMan
New member
Mind if I ask what the expensive repair was?
lennyzx11
Veteran Member
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- Bennington Vermont
- Tractor
- Kubota L3301 HST/LA525 & 1964 Ford 2000 gas
I have a 2011 bought new. I had this happen a couple of times during a hard rain when I first got the truck. I drilled the hole then and got the ECM tsb flashed. Never saw it again.
I changed the inter cooler to a racing type as I really wanted a hidden winch in that hole behind the stock bumper. During the next few days after installation, I would get a shudder or misfires pulling an RV uphill or getting into it.
I finally figured out that one of my intake hoses was opening at a loose clamp under pressure from the turbos spooling up. This would dump pressure. As this was after the sensor measuring manifold pressure, the computer would dial the fuel back causing the truck to go lean.
I changed the inter cooler to a racing type as I really wanted a hidden winch in that hole behind the stock bumper. During the next few days after installation, I would get a shudder or misfires pulling an RV uphill or getting into it.
I finally figured out that one of my intake hoses was opening at a loose clamp under pressure from the turbos spooling up. This would dump pressure. As this was after the sensor measuring manifold pressure, the computer would dial the fuel back causing the truck to go lean.
Snobdds
Elite Member
There is no EGR on Ecoboost. Never needed one with the direct injection. The direct injection has a very complete burn and only Nox needed to be scrubbed from the cats.
BandannaMan
New member
After the intercooler drain hole yielded no positive results, independent mechanic started looking around. Found misfire on one cylinder that was fairly regular. Ultimately, found two cracked plugs that were either cracked when put in the vehicle just two weeks ago, or cracked when they were being inspected at the local Ford dealer just this past week. Cracks had carbon deposits on them - he did not crack them taking them out - he inspected all 6 and ended up replacing 3 of them. Test drove it and the single cylinder misfires went away but the random misfires (all/any cylinder) continued. Did a fuel pressure test - all fine. Checked the MAF sensor and found it clogged with oil and crud. Cleaned the MAF, did a test drive and no more misfires! Late in the day so we too the truck so we could test drive it towing the trailer next AM first thing. Test failed, some small misfires going out of town, some big ones coming back in. Brought it back gave him results and he re-checked the MAF sensor - coated with oil again after only one hour of driving. Looked at the hoses coming out of each turbo and into the intercooler - the passenger side hoses were dry and a little dusty - the driver side hoses were covered in oil and crud. Popped the outlet hose off the driver side turbo and stuck his finger in, finger came out coated in oil. New driver side turbo is now on order, to be delivered tomorrow. Don't ask what it costs. 
We are hoping this is the root cause of the misfires.
Oh yeah, there definitely is no EGR on this vehicle.
We are hoping this is the root cause of the misfires.
Oh yeah, there definitely is no EGR on this vehicle.
Snobdds
Elite Member
The spark plugs have a specific torque value, like 11 ft/lbs, that it needs to be torqued too. So many people have had misfires after a spark plug change simply from over tightening the plugs. The boots should be changed as well.
I doubt the turbo is your problem. There is a TSB for early ecoboost for the hose that drains the oil back to the engine on the turbo. The connector is faulty and they just use a updated hose and connector. Hopefully this new Turbo has a updated hose.
Turbos on these things are cheap, relatively, around $600.
Try pricing out a Turbo for a diesel. Ecoboost parts are cheap compared to anything diesel...
I doubt the turbo is your problem. There is a TSB for early ecoboost for the hose that drains the oil back to the engine on the turbo. The connector is faulty and they just use a updated hose and connector. Hopefully this new Turbo has a updated hose.
Turbos on these things are cheap, relatively, around $600.
Try pricing out a Turbo for a diesel. Ecoboost parts are cheap compared to anything diesel...
The electric steering (these trucks do not have power steering like old) went out at 65K. Cost $1800 to repair and Ford would not help even though the truck was bone stock and had never been abused or driven in anything that could damage the steering like high water etc. No reason given, it just failed.
buickanddeere
Super Member
At light load and low combustion chamber pressure the old coils may have enough energy to jump the gap. Under boost the voltage required to jump the plug gap can be 4-5 times higher than at idle or during puttering around driving.
Has anybody tried measuring the exhaust system pressure at the inlet of the cat(s).