Looking for any help anyone can provide with an issue that I can't seem to get rid of.

Service visits:

May 16, 2012 - 55,228 mi (For misfire)
June 11, 2012 - 64,930 mi (For misfire)
Aug 06, 2012 - 66,202 mi (For misfire)

Needs service again for misfire now at 72,000

What they've done:

-Replaced all plugs
-Replaced 3 coil packs
-Replaced a single plug
-Reflash
-New left cat

Each time the symptoms go away but I feel like the underlying problem still exists that obviously is bringing the same issue back every other month or every month.

Before this was annoying but last night I nearly died passing a 18 wheeler when the truck fell flat on it's face with traffic coming.

Other than the misfire I love my truck

 

There has been a long string on the 2009+ forum about intercooler (IC) condensation build-up. May want to check that out.
https://www.ford-trucks.com/forums/1...n-buildup.html

 

Thanks, Tim. I'll be sure and read that thread when I get some time today.

It just so happens that my Ford dealer called this morning to tell me my back ordered intercooler deflector is now in stock.

 

Hopefully that will solve it.

 

Well took it in on the 24th and got it back on the 26th. Ran great on the way home and then back to the same old thing the next day.

From service ticket:

"CUSTOMER STATES: MISFIRING AGAIN. SOP PARTS HERE FOR INTER COOLER DEFLECTOR TOO. PLEASE CHECK AND ADVICE.
VERIFIED CONCERN, LEAN CODES, CAT CODES, LEAN MISFIRE CODES. CLEARED CODES, INSTALLED DEFLECTOR, NEW AIR FILTER, REPROGRAMMED PCM TO LATEST CALIBRATIONS, RETEST= OK. NO MISS POWER BALANCE TEST= PASS. 02 AND CAT SYSTEM WORKING AS DESIGNED NOW."

When I showed up to pick it up they tried charging me a hundred fifty some bucks and I made sure to remind the guy this was visit number 4 this year for the same issue. He went back and talked to his boss and got it covered under warranty relating to the deflector.

Anyways the truck drives decent around town for the most part but with any throttle load weather it be accelerating on the freeway or pulling a trailer you can feel it jerk almost like it's choking. However it will not do it as violently as it was before and so it hasn't thrown a light. Dealer is operating under the no codes = can't help you frame of mind.

Just absolutely exhausted with this. I love this truck when it's working right but at this point I'm trying to figure out how to throw down on another truck and move on.

 

Woohoo! Just heard my new charge air cooler was in and ready to be installed next week! Really hoping this fixes all my issues so I can stop *****ing Not to mention I'd like to start a bunch of projects on this truck!

On the other hand my battery gave out this morning with no warning! Always something!