F150 ecoboost drilled my intercooler

   / F150 ecoboost drilled my intercooler #141  
I missed it earlier that you bought this used. Hard telling what the previous owner did to it unfortunately. Could be your turbo just simple had problems at 94k miles, or could be there were other mods to the truck by the previous owner that contributed to its failure.
 
   / F150 ecoboost drilled my intercooler #143  
Whole truck would be junk by 100,000 miles.

Yeah, we know, Fords are the greatest things on Earth and all GM products are junk. Yet, my Silverado will run circles around any 150 ever made.
 
   / F150 ecoboost drilled my intercooler #144  
Yeah, we know, Fords are the greatest things on Earth and all GM products are junk. Yet, my Silverado will run circles around any 150 ever made.

Your Silverado must need an alignment! :laughing:
 
   / F150 ecoboost drilled my intercooler #145  
Your Silverado must need an alignment! :laughing:

Now that is funny right there, I don't care who you are.

Seriously, it might. 140k on it and it has never seen an alignment rack. I've put 2 sets of tires on it and for various reasons I didn't get the alignment done at that time and then "forgot." Still no signs of weird tire wear.
 
   / F150 ecoboost drilled my intercooler #146  
Now that is funny right there, I don't care who you are.

Seriously, it might. 140k on it and it has never seen an alignment rack. I've put 2 sets of tires on it and for various reasons I didn't get the alignment done at that time and then "forgot." Still no signs of weird tire wear.

Glad you took it as the joke it was! :drink:
 
   / F150 ecoboost drilled my intercooler #147  
Had a ton of transmission shudders on my '06 F-150 5.4 Triton and kept thinking I needed a new tranny. Would shudder in high gear when starting to climb up a hill. Would have to get into gas to drop a gear, then problem would go away or put in tow/haul mode to get out of that gear completely to get away from shudder. This went on for a while. I put in anti shudder, but didn't really help. Decided to change plugs that were misfiring when light finally came on and had read on Ford forums that this shudder could have been a misfire issue. Took about 2 months before engine light came on. Code said #3 and #7 misfire. At least it wasn't 4 and 8 I thought. Also bought a tester for the coils to check them while in there. They coils appeared to fine.

155,000 miles or so when I did that. Truck ran fine and had more normal power right away, just felt much better, but ever so slight shudder same as before in the 45-50 mph range in top gear going up hill.

Problem became worse again pretty quickly until it was back to full strength. Maybe 2 months or so max. This time the truck really felt violent and like it's timing was all off.

So changed all 8 plugs and all 8 coil packs while I was at it (they were much cheaper as a set then each one individually). Problem completely solved. No more tranny shudder whatsoever.

2 months later, problem comes back. I'm about to flip out, but this time check engine light came on immediately with problem. I get code read, #3 cylinder misfire. I can't believe it at this point. I just put all new E3's on based on the recommendation of O'Rielly and had brand new coil packs (did I mention the power was great again; better than new).

I hope it's just a plug at this point. I got another one, take it home, change it and the electrode of the plug I pulled out was missing completely. Never heard of that before, but problem fixed and going on 3 months now with no more problems at all and great power. Just putting this out there that what can feel like a tranny problem may not be a tranny problem at all. Also, this intermittent thing is frustrating. Went a long time with no check engine light and having misfire issues. Very strange to me.
 
   / F150 ecoboost drilled my intercooler #148  
As a Sr master Ford certified technician, with 2 years college in the Ford ASSET program and over 10 years experience, this makes my brain hurt!
That being said, I personally have never seen condensation cause a problem in any turbo system. Ford has been using air to air coolers since 1998 on diesels and before that in a couple turbo cars. If you make even the tiniest hole in the charge air system you will get reduced power from a boost leak. It would be ok if you really think this is an issue to drill the hole and tap some threads in it, but as I said, I have never seen this issue. If it is happening with a eco-boost building low boost pressure, wouldn't it happen worse on a power stroke building upwards of 40psi of boost? I would lean more towards fuel system, or exhaust system (ie cats restricted.)
 
   / F150 ecoboost drilled my intercooler #149  
As a Sr master Ford certified technician, with 2 years college in the Ford ASSET program and over 10 years experience, this makes my brain hurt!
That being said, I personally have never seen condensation cause a problem in any turbo system. Ford has been using air to air coolers since 1998 on diesels and before that in a couple turbo cars. If you make even the tiniest hole in the charge air system you will get reduced power from a boost leak. It would be ok if you really think this is an issue to drill the hole and tap some threads in it, but as I said, I have never seen this issue. If it is happening with a eco-boost building low boost pressure, wouldn't it happen worse on a power stroke building upwards of 40psi of boost? I would lean more towards fuel system, or exhaust system (ie cats restricted.)
There's no debating condensation was a problem for the F150 Ecoboost under the right conditions. Ford acknowledged it, released multiple TSB's with Band-Aid fixes, and eventually made several design changes to both the intercooler and the programming. It was part of the learning curve, but they seem to be over the hump after the first few years.
 
   / F150 ecoboost drilled my intercooler #150  
They only real issues I saw as an engine mechanic on these engines were turbo's going out (not very often, but would fill the cooler with oil and excessive smoke, and lack of power) and water pumps on the early engines. Maybe in other parts of the country, there was an issue, but here in humid Mo I have never heard of it. Also, to ad to my prior statements, drilling and not plugging a hole in the charge system will also give you a misfire, check engine light, and poor fuel economy(eventually fouling the converters) as it will be running off the factory mapped fuel code and expecting full boost so adding full fuel (look up diesel smoke switch or clogged air filter on a diesel)
 

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