2005 f150 intermittent sputtering while driving

The old one didnt look corroded or broken in anyway, but must have been faulty in some way.
I just wish I came to this forum before I spent 800 beans for the wrong diagnosis.
Yeah it was just bucking away. not always, which made it difficult to try to show Ford the problem. If I recall it was mostly around the 50 mph mark, but could do it at any speed.
04-04 F150 FUEL PUMP CONTROL MODULE 4L3Z-9D370-A 4L3Z 9D370 A 5L8Z-9D370-A - Photo ID 39355
Ford Trucks for Ford Truck Enthusiasts
Anyone able to confirm my suspicion that my electronic overdrive my be the root of the problem?
I've had my truck at the Ford Dealership for the past 2 weeks now. I took it to them due to code P0191 showing. It was running poorly, black smoke from exhaust, sputtering. The guy i bought it from told me the board was bad. I decided to try and fix the cheaper things first. So I replaced fuel pressure sensor. FPDM is in good shape. All compression test on injectors were ok. The dealership scanner pulled up like 10 codes my friends shop didn't (he had a very expensive scanner). All the codes they told me came up pointed to the Throttle body (which I had cleaned a week before). So they ripped me a new one charging me $700 for a new throttle body. I went and picked my truck up that day....drove fine otw home....next morning check engine light back on, same code showing, and same symptoms happening intermittently. Ford has came to me with different "could be" reasons....fuel injector....defective pressure sensor....even came to me saying that it seemed to be dropping pressure when turning the wheel one direction, which makes no sense at all.....or it could be electrical (which i told them from the beginning, about being told the board was bad) Any ideas?
It started completely unexpectedly about a month ago when I was driving around 70kmh while cruising. I would get a few "jerks" of a sputter, then was able to drive a km or 2 before it did it again. I drove to a friends and he got in, and the sputtering episode was over.
Since then, I cannot simulate the way I was driving to make it sputter for any mechanic, but I have been getting sputter on and off the last month.
The one time I got in the truck and started it, put the truck in drive, and it sputtered for a few seconds. I wasnt driving at all this time. This was the only time It sputtered in a stading position.
Here are a few points to maybe help narrow down what happens.
-I am usually driving around 70-90kmh
-I am usually under no loads (not towing, hauling etc).
-My mileage seems to be getting worse.
-this was normally happening not only when the engine was warm, but when it was warm outside and I was driving it for a longer period.
-When I started driving my truck I calculated around 16mpg city. I am currently getting around 13-14. I was on the hiway for around 250 km and got 14mpg. Seems I get better mileage when puttering through the city than when I am on the hiway.
I had the truck in to a dealer 2 weeks ago. They did an injector flush, new sparkies, number 5 coil, and took me for $780, saying the problem is fixed.
A few days ago, I was driving on the onramp to the hiway accelerating around 90kmh and for around 4-5 seconds I was sputtering and jerking so bad I thought I was done for. The truck finally recovered and again, havnt had any episodes since.
The dealership says their electrician doesnt know what to do, and would need my truck for 4-5 days to try to see the problem for himself.
I can only think, as a non-mechanic, that it is something to do with some sensor, possibly a fuel, and/or oxygen sensor.
Any thoughts, comments, questions are greatly appreciated!!!
2005 F-150
4.6
88000km
gas
I read about your issue. I've been having a sputtering issue with my 5.4 Triton v8 and asked a buddy at work if he'd experienced this issue since his f150 has the exact same motor. What he said was there a leak somewhere below the wipers that allows water to drip into and sit in the engine block, corroding the coils. I reached to the back of mine on my lunch break and sure enough, there was some play and a wet spot just below it. The guy told me a friend of his replaced the corroded coil(s) and coated them with silicone to waterproof them and it seemed to work.
Anyone able to confirm my suspicion that my electronic overdrive my be the root of the problem?
I'm taking a trip to PA. and N.C., so today I got a new FPCM and installed it as a "just because", and even tho the truck ran good before the new module, it's better now. Makes me wonder about my fuel pressure. Another thing to check pre-trip.
It is confusing to most people as they say I don't have a CEL so it must be okay . Some guys and shops have even done a trans rebuild for misfires because of the bucking .People also are very reluctant to replace boots because they look good even if they have 100k on them . They are fairly cheap and a lot of coils come with them . Not to mention those who still believe in a 100k plus plug change . That was a sales tactic and just causes grief especially when ford came up with failing plugs that seized in the head then broke off .
Next some people believe its normal to maint change all coils .Its not necessary as OEMs can get corroded terminals they rarely fail . Aftermarkets never worked for me in six months mine failed .I have 7 oem coils and one duralast guaranteed at 201k .You can't really believe you get the same thing as oem costing $50 each and after market $6, a really good high voltage coil takes high grade silicon steel and bubble-less epoxy of high grade .One turn to turn short on the thousands of turns knocks it to junk.
Not torquing in the plugs with a torque wrench to the higher 25-28 foot pounds leads to blowby and plugs destroying themselves. Plus it can launch the whole assembly taking some of the aluminum threads with it .
I can understand a shop trying to make money on plugs and being in a hurry and even not attempting the difficult ones . That's why we encourage guys to do their own ,you have lots of time they don't . I know there are engines that have to be pulled to change some plugs on older cars ,some new ones you have to pull the intake . So this doesn't rise to this level .
Split cops are abnormal they can't be oem . Too many guys like fancy colored ones and just like fishing lures they get caught --fish don't buy lures .
Damp weather and cracked COPS ,do you think that may have the high voltage shorting out with moisture !!! We have heard this also .
A very good code reader for this engine is the $5 torque pro app /amazon bluetooth reader around $20 bucks /android phone activated or not .
If you pressure wash this engine you better know your stuff .
Learn to do a really good plug job and take your time .It will be good for 60k .




