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As for cost ... I don't know. If you're under warranty, then you can get the dealership to do these without any expense to you. But, some dealerships won't just do it because you asked. If you have a particular mechanical, etc. problem, the reflash may help. Get to know one service tech on a first name basis and always deal with him ... and he'll take care of you like mine did. The following are taken from other threads about this topic ... read on:
Reflashing updates the engine management software with new and improved software. The Ford technical term for it is: "updated calibrations". You should ask if there is a newer calibration for your truck and see if they will update it for you. Some folks with the 3-2 downshift clunk said it helped.
If you are familiar with computers at all it is also very similar to why video card and sound card manufacturers come out with updated drivers for their products almost monthly when they release a new product. The first few versions of software usually show up with "bugs" when released to the public in many different setups and conditions so they update their software to fix these bugs......same thing with the computer software in your truck!
one dealer told me about $45.00, (i think he said .8 hrs) but ran my vin and said there wasn't any new flash upgrades for my truck, so really no reason to do this, unless i was having some problems. so i think i better let well enough alone. i'm thinking seriously about a tuner, mines a 4.6 scab, but not really broke in yet, w/2100 miles, i wish i had got the 5.4. paul
i understand that all you do is plug in your device, set everything back to factory, unplug it and they wont know about it. someone correct me if i'm wrong....paul
I've bugged twice now with the service manager to have the PCM Flash done. This last time I said, "Well, the throttle response is lagging off the start and in my research I found that the software update can, in some cases, fix this." At that point he said, "Well, it sounds like an easy fix then." I assume that means they are doing it when it goes in for service next week. I also have the downshift clunk symptom which I forgot to tell them about (nor was I aware until I read this thread that the flash update can fix this). So if they say "no" again, I've got more ammo to throw at them to do it. I've only had the truck ('04 screw w/19000mi 5.4L) for about a month so I've yet to get real pushy with them. I hope I don't have to.