So maybe I should entitle this BandannaMan's awesome adventure...
Except, ..., it is not so awesome as we are now cancelling the continuance of our two month trip and headed home. Why, little to no confidence in the tow vehicle.
Got the truck back from the independent mechanic here in CO, he replaced CACT/Turbo Pressure sensor combo that is in the pipe between the CAC and the throttle body - no joy. He then noticed tape residue (duct or electric) on the electrical plug for that sensor and thought that was odd. He spoke to Ford - NO, that's not odd, that's normal because the wires and plugs used in these models are subject to failure due to inadequate strain relief! Order the new plug, takes another day, install it - truck runs fine! No limp mode, no error codes, no misfires. Of course, we haven't towed with it yet - that will be tomorrow.
Anyway, here's what I have learned indirectly so far about this experience:
1. Never try to fix a problem you don't understand. For example, get a rock solid diagnosis first before "throwing" a fix at something to see if it will go away.
a. When first misfires started happening, Ford told me to replace plugs and boots to see if it would go away. I did and they were due in 5k miles anyway, so no biggy right? Except for one thing, plugs can fairly easily be cracked if you don't have the right tools simply by taking them in or out! When the first indep mechanic checked the new plugs he said two were cracked while they were put in or while they were subsequently checked by Ford - carbon trtacing on the cracked plugs. Yes he cracked one taking it out (clean crack), but told me up front - honesty wins all.
b. Two PCM reflashes to no avail. Basically a waste of time. Additionally, Ford could not answer why the reflash was necessary. Was the PCM bad, was there a ground problem, a voltage spike problem coming into the PCM - no answers, they just stare at their own feet.
By the way, as an engineer and a software writer, I always said "80% of fixing any problem is finding the root cause of the problem". As a customer, there are no stupid questions - ask them all and ask them to explain everything they say - basically apply a BS test to what is coming out of their mouths. This takes time, be patient!
2. Always test a fix under the same condition (load, speed, etc) that originally caused the problem. In our case, it was (and still is) hook up the trailer and go climb a hill at highway speed in low engine rpm (~1500-1600). Three of the four times Ford "fixed" the problem, the problem reappeared within an hour of repeating the original test condition. The fourth time Ford had the truck, I said no thank you from any proposed fix (CAC tsb to block it with plate) and went elsewhere. When the independent replaced the turbo, I did test the next morning and the next 4 days and all seemed well. By the way, I truly believe that replacing the turbo was absolutely necessary. The original turbo that went bad caused some down the line problems - more on that later. This takes time, be patient!
3. Always talk to the horses mouth, and get your old parts back. The service "reps" (?) that you talk to when coming in for service are salesmen and are there to sell you service - I now believe they will tell you anything to justify the bill. Go around them, either up (service manager) or down (service tech), preferably both. Ford service "reps" have "misinformed" me on several things along the way, when I caught them on it, they start to shut up - hopefully they listen at that point as well, but don't count on it. The old parts tell a story of what has transpired, and mnore often than not, it may take some time (and more knowledge) to fully understand the story they are telling. The plugs and boots originally replaced were all in excellent shape - turns out, for my case, they were screaming "we" aren't the problem. I now have a used CAT/pressure sensor and electrical plug in my possesion - we'll see what story they tell.
4. The 3.5 L ecoboost is a powerful compact power package, but it's a prima donna. Yes, it pumps out the HP and torque in a nice package when it is working well, and yes many people love this engine, I understand why - no issue there. BUT, it evidently needs an extreme amount of TLC, especially the earlier models.
a. I don't know why my turbo failed - it could simply be the amount and duration of load I have placed on the engine by towing my 6500 lb trailer some 23,000 miles in three years. Yes, things fail under load more often than not, but this reason for the turbo failure is conjecture only on my part. (I could not get the turbo back as it would have cost an additional $450 core charge to keep it).
b. I don't know why the CACT/turbo pressure sensor combo failed (or even if it did at this point-most likely not, because a new one did not resolve the problem and replacing the electrical plug for it did solve the problem (subject to further testing)). The story of the electrical plug is interesting though - the first indep mechanic thought this sensor was the MAF sensor - it is not. He MAY have removed electrical riginally wrapped around the plug to provide strain relief for the wires - he did not say whether he did or not, it never came up by him or me. For that manner, the prior owner of the vehicle may have done so as well. However, in cleaning the sensor it is best to remove the plug to do so - he did this twice and I, myself, on his guidance and advice, also did it twice to remove oil from the sensor inside the pipe. Neither of us concerned ourselves with the strain relief on the wires nor treated them with the respect they evidently need to work correctly. The second independent mechanic noticed the tape reiude on the plug (good catch) and actually thought something fishy was going on - bad repair or whatever, until he spoke to Ford who told him that the elctrical tape is supposed to be there and is shipped that way from the factory because of problems with the wiring and that plug.
c. Cracking plugs when putting them in with no way to tell if they are cracked once installed is a bad situation, especially if they are touchy (sophisticated) plugs, special tools and skills are required to imnstall remove, etc.
Now hopefully, Ford is learning from this and improving these little things in later model years.
We are $2500 poorer this year due to this original random misfire problem at this point (still in testing). I have spent another $1500 on getting my 4 Low fixed, brake job, and fixing a flat. This is getting expensive!
My experience is with a Ford product, because that is what I bought. There is nothing to say that these problems do not happen with other manufacturers, in fact, I am sure they do. I always liked the way it rode, the way it looked and felt, but reliability is obviously become a problem. If I bought a V8 gas, or turbo diesel, I MAY have been better off at this point - can't really tell - every vehicle is it's own beast. I like the Dodge Ram Cummins combination but as one of the mechanis told me during this soap opera, "you buy a RAM for the powertrain, then you put up with everything around it".
I know I am long winded, but I am an ****-retentive, left brained, son of a "gun" - can't change who I am, at least not too quickly. Hoping this helps some others at some point - give back to those from whom you get!
