This weekend, I visited family and put over 600 miles on my 2001 Ford Expy XLT 4x4 with 5.4 with 134K miles. I ran highway speeds, well maybe a little over, and had no problems, other than paying $2.98 for fuel in Oklahoma (50 cents more than when I filled up around home).

Yesterday morning, the truck ran fine, and I happen to find a 7-11 with regular unleaded for $2.49 (so I U-turned) and put in 15 gallons (I was in a hurry and didn't fill up). Normally, I fill up at a good quality Shell or Exxon station, but couldn't resist. I drove on to work without a problem.

After visiting this forum from the office, I leave to go home and everything appears normal as I enter the ramp to get on the highway during "RUSH" (a.k.a. Slowwww hour) and as I accelerate to 50mph, it was if someone applied the brake and the truck slows down to 15mph (that will not work in Dallas traffic). I pull off the ramp, across 3 lanes of traffic (everyone was wanting to get on the ramp, and I wanted to get off and into a parking lot). I was able to get to 30mph, before it again felt like someone applying the brakes. There was no sound (not even the clutch fan when I attempted to take off, but it was only 88 degrees) or any lights to indicate a problem. I made it 2miles back to the office, before I decided to call a mechanic and then a tow-truck.

Over the phone, before they even had the chance to examine, the mechanic indicated that it sounded like a clogged catalytic converter, as this same thing happened to him in his Ford Truck.

On Friday, I had the oil change, and it appears that everything else (Airfilter and all) according to the inspection sheet was fine.

I was wondering if it could be bad fuel, and possible an fuel filter, or is it the catalytic convert (it passed emissions just 2 months ago).

If it is the catalytic convert, does it just show up like this without any previous indications?

I had a 6:00pm appointment to check out a 2002 Limited Expedition at a local "Hummer" dealership. I still plan on keeping my Expy, because it is paid for and has served me so well.


Thanks for you opinion on this possible problem.

I had the truck tuned up at a Ford delership with the past 8 months (didn't see any performance improvements) and I don't know if replacing the fuel filter is a standard procedure during Ford Tune-ups.

 

Had a calytic converter clog on my little car and the engine rev but no power. it sounded as tho the trans was slipping. Trans shop checked everything in the trans and checked ok. After driving the car he called and said it was converter clogged. Removed and car ran fine. Check fuel filter. Could be clogged if the gas was bad.

 

Mechanic no longer thinks that it is the Catalytic converter, and indicates when you check the fluid for the front differential (transfer case) it smells like burned plastic, and indicates there are several wires in there they may have shorted/burned.

Sounds expensive!!! Anyone experience this problem and take the time to share.
I'll start another thread..

 

Just dealt with a clogged cat myself. The mileage dropped slowly over a year or two as it clogged up. The truck was also gutless and smelled like sulfur when pulling a 3klb popup trailer in the highway.

Is this a Ford dealership that you took it to?

 

No.. but that sounds like a good (better) idea. The closest Ford dealership, (where my tow company through Geico would tow) didn't have a Full Service Center (they could do oil changes and such, but had to take it to another dealership for more complicated work).

I took it to a "City Garage". I had been taking my past couple of trucks (Ford Ranger, Ford Explorer, and now my Expedition) to a local "close to the house" Ford dealer, but one dealer took over 5 days to change a thermostat (claimed that their diagnosis equip. was down) and I pulled it from them and pulled into a local city garage that did it in 30 minutes (they had to wait for it to cool down).

Years later, the check engine light on my Expy (replaced my Expedition) came on and I decided that with 120K miles, it might be time for a tune up. Ford was actually cheaper than City garage (by over $130) and when I took it into this other Ford dealership, I specifically requested to see all 8 spark plugs (as I heard that some shops will intentionally refuse to replace the back 2 as they are difficult to reach. After a few hours, the mechanic returns with 6 spark plugs, and indicated he had tossed the other 2 (I immediately lost trust and confidence in their shop) and then tells me that the "Check Engine light" was due to a thermostat, "would you like me to change that and clear the code"...hmmmm. I was still impressed that I got over 120K miles on the same set of plugs, and it didn't run any better after the spark plug change .

I have always purchased my Ford vehicles from the same place my parents purchase their Ford Vehicles, and they do great work, but they are in anther state 200 miles away.