Well, last Saturday the wife and I got a babysitter and headed out to dinner in my 05 KR. We got about 3/4 of a mile when the engine started shaking, idling rough, and lost all power. I thought it was a PCM error; we turned around and limped it home. As soon as I got it in the garage it started knocking. I shut it of immediately. We took the wife Expedition to dinner with hopes that a PCM reset would solve issue. On Monday the Ford dealer pick up my truck and hauled it to the service dept. On Tuesday they notified me that the engine was toast and I should come over and take a look. When I arrived they showed me the engine hanging on the cherry picker, pan of and dripping oil. The tech handed me a flashlight and said check out cylinder # 1. To my dismay the rod looked like an "S".

The tech explained that the injector had stuck wide open and hydro-locked the cylinder. The damage... bent rod, broken piston skirts, damage to the front counter balancer, and shattered piston.

The dealer had already ordered a new engine, which will be here Friday due to the holiday. But to my great surprise, they said the truck would be ready for pick up Friday afternoon.

 

Bummer news, but glad they are going to fix it fast for you. This is one of those times where you say "thank God for warranties!"

 

Its good to see a positive experience with a dealership, that is how things should be handled. Good luck with the new engine.

 

You have a good dealer

 

This could be the start of something horrible.

Glad it all worked out for you!

 

Hey guys, whats with these injectors sticking open?! Could they be causing our rough idle and is there a way to check these injectors? My concern is a damn injector sticking open at 36,001 miles and we have to flip the bill for a new engine. If this is a common problem it needs to be addressed.

 

I've read of this concern on Ford's dealer message boards, but I haven't seen it personally yet. I haven't heard of any identifiers or commonalities with engines that blew up 'cause of this either. Doesn't sound good in any case.

 

Honestly, Im kind of worried. My truck has been varying in RPMs while cruising.

 

I had my #8 injector stick open on me on the interstate with cruise on. I didn't notice a problem until I was slowing down for a off-ramp, which is when the CEL came on. The truck had about 5000 miles on it. I pulled it into a dealer in the middle of nowhere and they found the problem. They also advised there was a TSB that told them to replace the injector, all 8 plugs, and change the oil. When the truck stated shaking, almost wanting to kill, I only had 2 limp it about 2 miles to the dealer, so no other problems resulted of this stuck injector. No problems since then. The tech that worked on my truck said he only ever saw this happen on one other expedition 5.4L.
-Mine is a 5.4L

 

Bad injectors will definitly cause a ruff idle.I guess that's a sign for bad things to come.

 

Well its not a good sign when Ford dealership says this idle is normal. So :thumbsdown:

 

Have all the stuck injectors been on 5.4s?
They don't use the same ones as the 4.6, do they?
Design flaw?
Chris

 

My dealer said it was a total fluke. I guess I get to beak in a new motor and find out

 

Yikes. The 4.6 is looking better every day the way things are going!

 

Yeah, I dont think anyone would have guessed there would have been this many problems with these 5.4 engines, and sadly enough, there are going to be a ton of them out there. But dont get your hopes up, even though the 4.6 may not have problems, it is grossly underpowered, although the 5.4 isnt much better.