2004 F150 STX, 4.6L, auto, 4x4, 142,000 miles.

When in for oil change and routine maintenance with local shop mechanic, the truck first refused to start, then went in to safe idle mode. was taken to a large "reputable" Ford dealer in Northglenn for diagnosis/repair. It was determined that the throttle plate control had failed, and the return spring, etc was in bad shape. I gave the go ahead to replace the throttle body as that is the recommended repair.

The truck still did not run... codes showed failure of the Powertrain Control Module "the drivers are gone" and it was tested with the PCM from a different truck and it ran fine with that. Again, I gave the go ahead to order and replace (ouch) and after a week and a half of backorder and nearly $2000, it was installed and the truck ran.

It did run better than before failure, but not an impressive change. A week later I took in on a trip of about 800 miles, and it failed again. I was stranded.

It is now with the hometown Ford dealer. They have determined the PCM failed AGAIN after thorough testing, and expressed concern that it may not have been installed properly the previous time. I am now waiting to go back to get it.

In both cases, the only corresponding events were that the truck had been driven through some standing water, not very deep. Mechanic said that system should be waterproof enough for that situation.


Has anyone had experience with failing PCM? The cost of the second is covered under repair warranty, but the loss of work time and use of the truck (its over a month now) is getting old.

thnx

 

I've heard of the super duty's having pcm problems but this is something different.

Hopefully the techs are checking the power supply and grounds to the pcm with the wiring harness making sure that's ok also.

Don't know what else to say........

 

Think they've checked about everything there is to be checked. The truck has had a history of odd shifting under certain circumstances that was brought in under the original warranty. Of course they didn't find anything wrong with it, but thinking its related.

 

i agree with 88 racing, this sounds like something is shorting out, and burning up the PCM, to me.

 

Waiting for the part...... week to 10 days to get it.

 

The dealer shop has now stated that Ford has not been able to locate the PCM part, but has yet to put it on backorder.

Once the new Module is installed, the truck is scheduled for further diagnostics and testing to find the fault. I do believe now the previous dealer shop installed the new part, got the truck running, then quit any further work to determine cause or testing to make sure it was working properly.

 

Dealerships are great at throwing parts at a vehicle to fix it, cause they still get paid later if it comes back with the same issue

I agree there is another issue causing the PCM failures, they simply do not go bad like that.
Part of my job is to try to kill these things on the bench, and I have no success doing that.

 

Spoke with the shop today; they are still trying to locate the part using a nationwide "search" and talked with their District Service "Manager". He blew it off as nothing important.

I called Ford's Customer Service number, relayed the information so far and heard "I'm so sorry for your trouble" and "I completely understand ae nd empathize with you" enough times I almost puked.

I specifically told them not to chew out the shop because they are being held up by Ford's lack of parts availablity, but they called and told them to get on it anyway. The parts manager told them a thing or two.

The "supervisor" in Customer Service looked into it, and said that many of the outsource vendors have gone bankrupt and Ford is finding other sources for parts, if you can believe that.

It would appear this could be another two weeks or more.... Good God.

 

Diablo Mike... have you bench killed one of these by causing it to "lose its drivers" ?

Is there aftermarket/performance PCM's available?

Thx

 

Call some of the local autoparts stores.

I've gotta couple around here that sell them and do reflashes.
But.....
If you go that route you may not get as good as warranty as Ford is giving you even though you are having to wait.

 

have you tried a hammer, maybe a blow torch. i bet i could kill one on a bench.

 

Had a “kind-a” similar problem with my 04. NO-start, then limp home mode so off to the dealer I drove (slowly). Code was reading bad throttle body, and it was replaced and the dealer sent me home. The next day the same issue, took it back again and now PCM failure due to no drivers. Dealer re-flashed the unit and sent me on my way. The next day I had the same issues. Called a friend in Dearborn and found out that Ford was having an issue with the connector under the dash that connects the accelerator position sensor to the main wiring harness. Called the dealer, they cleaned and reassembled the problem connector and the issue has not returned in 150,000 miles.

 

Interesting........
One little connector caused all that grief.

 

Thnx on the connector!!! I will relay that to the shop ASAP!

(still concerned that failure has been associated with water)

 

The new/rebuilt (whatever it is) PCM has been delivered. Dealer shop wants to spend time diagnosing the cause of the failure, something that the previous repair facility did not do. I did relay the information regarding the under dash connector, hoping that does explain the problem.

Truck has been out of service going on six of the last seven weeks.