I own a 2005 F150 and have had it since new. The truck is a 4x4, supercab with an 8' body, 5.4L, with 32,000 miles.

Driving last weekend, the truck started running rough, lacked power, and the check engine light began flashing.

My mechanic's garage was only about a mile away so I proceeded to his shop and dropped off the truck. He got back to me on Monday and said the engine locked up over the weekend because of a stuck fuel injector. He said he'd replaced the injector but it didn't seem to be running right and he wanted to keep it for another day to check other things out. Today he called me and said the catalytic converter was plugged and needed to be replaced. He suggested I bring it to a dealer since it was still under emissions warrantee.

I called one dealer who stated if the truck had a misfire the cat would not be covered under warrantee. He went on to say that they would only cover the cat if the truck failed emissions.

I called a second dealer who was more helpful but said they'd have to check codes, etc, to determine what caused the failure.

I am having the truck tower to dealer #2 tomorrow.

Has anyone gone through this and have any suggestions, advise? Mt mechanic said this cat could cost 1500.00!!

 

Yes, I went through it with my 2006 Expedition 5.4L. A bad injector caused the cats to fail. They ended up changing both cats thinking they just went bad, then identified a bad injector on bank two and had to replace the drivers side cat again. Nominally, the dealer will only replace a cat under the emissions warranty if the failure isn't due to another problem upstream. But they covered all of mine. I'd just let the dealer check it out and not mention the misfire and bad injector. They can refuse to cover it if they know that a bad injector flooded the cat.

If they don't cover it, yes, it's $1500 for the dealer part. But you can find cheaper ones in the aftermarket. Of note, there has been a big shortage of cats for these trucks nationwide (at least there was earlier this year). Probably because these injectors stick open ALOT. When they fail they are suppose to fail in the closed position...oh well.

 

Thanks for the quick reply and advice. I will not mention the injector and see what happens. I'd really be upset if they refuse the warrantee claim. You'd think Ford would back their product especially with only 32000 miles, but I guess these days you can take nothing for granted with manufacturers warrantees.

 

Well I think the issue is that dealers are having to wait longer to be reimbursed for warranty work so some are trying their best to avoid doing any. It is a sad thing to say but it happens. Anyway best of luck and I hope the second dealer works out better for you.

 

Here's an update. The dealer called and said that the plugs and coils on cyl. 2 and 3 need replacing, and the cat was OK. Cost for this work to me about 400.00. I approved the repairs and wanted their assurance that if it was the cat they would warrantee that work. He said the truck was out of warrantee (stated it was 5 years, 80000 mi) and it wouldn't be covered since the truck is older than 5 years.

He called back the next day saying it was the cat was NG and that the misfire caused it to fail, but then surprised me when he said it WAS covered and he had the wrong part number before.... I don't know but I'm glad I don't have to pay.

Bridge. You were correct about the shortage. It will take until early November for the cat to be delivered.

Thanks to all.

 

Make sure you test drive the rig with your service rep PRIOR to accepting the repairs and cashing out. Make sure you floor it to WOT a few times. If you hear any popping or missing u-turn back to the dealer. $400 is a little pricey for two plugs and two COPs, but if you're not a DIYer its not that bad. The cats should be covered for 8yrs/80K miles.

Keep us updated!

 

I believe there is an extended warranty for the injectors on these vehicles. At least I got a notice from ford a while ago. I think it was extend to 10 years 100,000 miles or something.

 

Yeah, I know that's pricey but I didn't have much of a choice since the dealer needed to diagnose prior to replacing the cat. In the future I will probably replace the remainder of the plugs and cops.

 

The warranty on the fuel injectors I received from Ford states the warranty is 10 years, 120,000 mi.

 

You could have had the bad injector replaced at the dealer for free plus any related damages (bent rod from hydrolock, bad cat) covered as well. The warranty on the cat is 8yrs/80k miles not 5yrs. Make sure you change the oil and filter ASAP too from the fuel diluting it. The recall on the injectors is called 07M08. You can possibly get a refund on what you paid the mechanic from the dealer.

 

Big trouble with F150. I just spent 2 weeks getting an injector replaced that I'm told may have caused the Catalytic Converter to fail. I had to go to another mechanic to detail the problem since Ford initially would not cover the replacement. Now 8 days later the other Catalytic Converter has failed and Ford has rejected the replacement because an injector on that bank of cylinders has not failed? Now I'm going back to the mechanic that assisted me the 1st time to have my engine checked. I no longer trust Ford..........

I called Ford customer service and got nothing but rudeness and they refused to transfer me to a supervisor. I'm now going to put a " I bought a Limon " sign on my truck and park it infront of the dealer. Perhaps I can at least stop a few lemon sales from occurring.

This is a lot of expensive BS. No more Fords! I thought I was doing the right thing by buying American and now see that I should have bought a foreign make.

 

Buy a foreign and be happy. I'll keep my ford

 

I just replaced my cat for 700 from my mechanic I bought an eastern cat for 500 free shipping it's not that hard of a job so labor shouldn't be to much