Intercooler Condensation buildup
Thread Starter
|
Posting Guru
Joined: Sep 2011
Posts: 1,088
Likes: 1
More discussion, and links on page two to patents seeking to fix this. Note reference to GM and VW, so this is not a "Ford only" problem.
Intercooler condensation - Ford F150 Forum - Community of Ford Truck Fans
Condensed water in intercooler piping - TDIClub Forums
Probably answer is some kind of reservoir or catch can that purges itself periodically.
Intercooler condensation - Ford F150 Forum - Community of Ford Truck Fans
Condensed water in intercooler piping - TDIClub Forums
Probably answer is some kind of reservoir or catch can that purges itself periodically.
Super Moderator
Joined: Apr 2004
Posts: 34,494
Likes: 2,809
Yea, with all the gas turbo motors out there, this has to have come up one way or another. I had an '04 Audi A4 1.8 turbo, never had a hiccup even in a rain storm that had me hydroplaning and spinning the tires on a very slight hill at 60+mph.
More Turbo
Joined: Dec 2011
Posts: 739
Likes: 393
The Ford patent noted in one of the other links ( CONDENSATION TRAP FOR CHARGE AIR COOLER ) was filed in Oct 2009. The published date of the drawing was April 2011. Wouldn't that design already be in the IC for the 2011 trucks if thought it worked?
Thread Starter
|
Posting Guru
Joined: Sep 2011
Posts: 1,088
Likes: 1
The Ford patent noted in one of the other links ( CONDENSATION TRAP FOR CHARGE AIR COOLER ) was filed in Oct 2009. The published date of the drawing was April 2011. Wouldn't that design already be in the IC for the 2011 trucks if thought it worked?
More Turbo
Joined: Dec 2011
Posts: 739
Likes: 393
If you search patents for "charge air" there are numerous patents to extract or control moisture in IC's. I wonder how many, if any, are actually used.
Moderator
Joined: Jul 2011
Posts: 6,509
Likes: 662
From: Sioux Falls Area
I dont think it has so much to do with whether it works or not, so much as it has to do with whether they thought they could do with out it.
i'm sure there was a cost analysis involved, and based on the testing conditions the prototypes saw, they decided it was not required.
we know that the condensation traps work, as other manufacturers are using them. I expect that they will issue a TSB at some point for a retrofit to be installed on vehicles which develop a problem. I also expect that new models will come equipped with a trap at some point to eliminate the problem for the entire model line.
but i've been wrong a time or two, so who knows ...
i'm sure there was a cost analysis involved, and based on the testing conditions the prototypes saw, they decided it was not required.
we know that the condensation traps work, as other manufacturers are using them. I expect that they will issue a TSB at some point for a retrofit to be installed on vehicles which develop a problem. I also expect that new models will come equipped with a trap at some point to eliminate the problem for the entire model line.
but i've been wrong a time or two, so who knows ...
Senior User
Joined: Dec 2009
Posts: 114
Likes: 0
I dont think it has so much to do with whether it works or not, so much as it has to do with whether they thought they could do with out it.
i'm sure there was a cost analysis involved, and based on the testing conditions the prototypes saw, they decided it was not required.
we know that the condensation traps work, as other manufacturers are using them. I expect that they will issue a TSB at some point for a retrofit to be installed on vehicles which develop a problem. I also expect that new models will come equipped with a trap at some point to eliminate the problem for the entire model line.
but i've been wrong a time or two, so who knows ...
i'm sure there was a cost analysis involved, and based on the testing conditions the prototypes saw, they decided it was not required.
we know that the condensation traps work, as other manufacturers are using them. I expect that they will issue a TSB at some point for a retrofit to be installed on vehicles which develop a problem. I also expect that new models will come equipped with a trap at some point to eliminate the problem for the entire model line.
but i've been wrong a time or two, so who knows ...
Cargo Master
Joined: Feb 2007
Posts: 2,474
Likes: 24
From: ME
This problem seems to be more common to people who baby their trucks trying to get optimum fuel mileage. I've been driving the wheels off mine and haven't had this or any issues in 14 months. 
If I cared about fuel mileage I wouldn't have put 34" mud terrains on it.
If I cared about fuel mileage I wouldn't have put 34" mud terrains on it.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
Thread Starter
|
Posting Guru
Joined: Sep 2011
Posts: 1,088
Likes: 1
I guess Ford has that option. However, if they would do that, and I would be affected by the problem, this would be my first and last Ford vehicle, as that behavior would just suck. :-(
Super Moderator
Joined: Jan 2008
Posts: 40,024
Likes: 1,519
From: Maine, Virginia
There is a fella on my route who has an earlier Mazdaspeed (protoge'). His license plate bracket is offset and his intercooler is wide open and up front. I've been trying to catch him to ask him if he's ever had any issues of any kind.
I only bring this up due to Ford and Mazda's past marriage.
I only bring this up due to Ford and Mazda's past marriage.
Thread Starter
|
Posting Guru
Joined: Sep 2011
Posts: 1,088
Likes: 1
My wife drives a 2003 Passat with a Turbo. There is nothing visible from the outside that it has an intercooler, not extra opening, etc.
We have bought the car new 9 years ago, and now after 93K miles, there has not been a single issue with the engine or intercooler.
But hey, I have not seen the issue with my truck either. Living in the pacific NW, one would think it has to be really bad here in the winter months with all the moisture and rain, but apparently not .... ? Maybe the temps are not high enough when it's wet, I don't know.
We have bought the car new 9 years ago, and now after 93K miles, there has not been a single issue with the engine or intercooler.
But hey, I have not seen the issue with my truck either. Living in the pacific NW, one would think it has to be really bad here in the winter months with all the moisture and rain, but apparently not .... ? Maybe the temps are not high enough when it's wet, I don't know.
Senior User
Joined: Dec 2009
Posts: 114
Likes: 0
Thread Starter
|
Posting Guru
Joined: Sep 2011
Posts: 1,088
Likes: 1
If so, then I am surprised you are still here, with a Ford.
Super Moderator
Joined: Jan 2008
Posts: 40,024
Likes: 1,519
From: Maine, Virginia
IMHO there was not one reasonable excuse for a single one of these issues and for a customer to have to come off the hip big to make the repair.
Does Ford keep a lessons learned folder? I'm not an engineer but, I rode Naval and Coast Guard ships for 24 years. At a minimum we kept very good records of things that worked and thing that did'nt, re-inventing the wheel can be painful.
Senior User
Joined: Dec 2009
Posts: 114
Likes: 0