2005 5.4L COP/misfire
 

I bought a new 2005 F-150 FX4 in January of '05 with a 36,000 service agreement (& 2 free sets of tires). Shortly after completeing a 35,000 mile service (covered) I began getting service engine lights. I went back to the dealership at 39,000 and they charged me $75 to tell me that it was the #7 COP & plug misfiring - 285$ to repair -- NO THANKS! So when the light came back on I stopped by my local AutoZone who told me it was the #5 cylinder. Being a 2005 out of warranty I asked for the parts - turns out Ford REDESIGNED EVERYTHING in this new itteration of this motor - 9/16" plug wrench needed (had to self manufacture) 17.99$ spark plugs - special order from Ford only (Motorcraft P/N:PZT2F) & new COP design (Motorcraft P/N: DG-511 ($60)). With a new one of each in hand I replaced #5 cylinder - only to now (4,000 miles later -- waiting on parts from Ford) to get 3 codes; 1- #5 misfire 2- Random misfire 3- Bank #2 to rich. In lieu of replacing the $180 special order (7/8" nut) O2 sensor I removed it and cleaned as best I could - ran great for 100 miles. Now with 44,000 miles & 80$ worth of parts I am right back to square one. I have pulled all COP's & plugs on bank #2 - cleaned, greased, reinstalled, moved new COP between all plugs on this bank.
I have read a TSB that says the block may need to be replaced... covered under normal warranty -- which I am no longer under. How do I get the dealership to do the appropriate tests to figure out if the block does need to go? I found #7 spark plug to have oil residue on it. I do have a 45,000 mile powertrain warranty - which is almost up!
What can I do to try to eliminate this issue? I was getting about 15-16 MPG's - now down to 10-11 (depending on wind direction - no issue due to my company paying for my gas).?
Any thoughts/suggestions/help?!?!?
peter.dutkowsky@ferguson.com

Take your truck to the dealer and explain, nicely, what you have found. Show them the TSB. Ask them to do the checks listed on the TSB.

If they won't/can't/refuse, call Ford Customer Service and explain the problem. Be sure to keep all of your records.

If you're coming up on the warranty expiration mileage, get it in quickly so you can have the problem documented.

Let us know what happens.

Hey my 04 scab is getting the same mpg. God help me trying to get the stealer to do the right thing and check it for problems under warranty.

Warranty expiration has come and gone - they want 75$ everytime they see my truck.

I pulled the #5 spark plug again today - to my dissapointment it was coated with raw uncombusted fuel....

I had the same problem with plug coating, but never had any code!, can anyone please tell us about the TSB mentioned in the original post.

regardin the plug, Did you try to replace plugs with 1F version?

Thanks

'04/'05
 

From what I have seen of trying to purchase parts from '04 models & looking at the engines they are totally different. Very similar in design but past the block & heads they changed everything they could. Trying to make sure they can get as much money out of us buying 2005 models as possible.
That being said I am not sure your problem is exactly the same as mine - however it may be - I'm no expert just a shade tree kind of guy.

2F I beleive.

Go and get an injector for cylinder 5. Have been doing a lot at the dealer. The reason for your rich codes is the injector is staying open, allowing fuel to keep flowing into the cylinder. And be careful with the plugs, because they strip out and break it the head easily.

Does it stay open due to the computer - or is the injector itself malfunctioning?
What is the root - Is a bad injector causing a rich condition which causes a misfire? Or is a misfire causing a injector to be bad?

Most days I wish they had stuck with carburators & no computers...

Thanks for the advice I will check in with my local dealership today and see if they have one in stock & it is affordable.

I went to the dealership this morning hoping to get some form of resolution. Thanks to the knowledge of others posting here & the TSB's I found on this website I was able to get the dealership to concede they misdiagnosed the problem & needed to help. They have offered to pay 80% of the repair costs -- even though they could not give me a full estimate until they pull everything apart -- roughly 200$ my cost. They however could not furnish me with a loaner & refused to pay for a rental, luckily for them my company has several spare trucks (F-250's) which I am now driving until they can make everything right.

I will post tomorrow when I hear back from them for time frame & costs.
They agreed that it was probably stuck injectors - most likely on #5 cylinder (which they said never had a problem before...).
Other than getting parts prices from another dealership before I pay them any suggestions on how to protect them from trying to say it was a 10,000$ bill (20%= WAY more than I am willing to pay)?

Peter
PS: I had a copy of the TSB in hand -- this made them somewhat upset -- they knew their worst enemy had stuck again ---- The Internet!!

yea have the replace with the same old malfunctioning part there has been no updated part for the injector issues on the 5.4 l in 2 years now.

my o5 had number 25 and 7 injectors stuck open and it took them less time to fix than an oil change. dont let them milk you for the defective technology

Here's what I know - they replaced the #5 & #7 injectors, put 3 new spark plugs in (why 3? i don't know), put in 2 new catalytic converters, and cleared the codes in the computer - what they did that they won't tell me about I have no idea. They charged me 105$ which by my math was 20$ high but my time is worth more than 20$ an hour - so screw them. 105$ could have just bought them a customer who WOULD HAVE returned - they didn't and I won't.

I am happy to have my truck back - it was much nicer to drive home in last night than the '05 4dr slvr Taurus I drove for the last 2 days. 105$ was a small price to pay - I am quite upset that they handled it the way they did and I will be sure to spread the word locally about said dealership being crooks as well as calling Ford Consumer Affairs.

Thanks again for all the help with this one.