Reoccurring COP failures

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Old Nov 1, 2011 | 11:36 PM
  #1  
BrianD's Avatar
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From: Garland, TX
Reoccurring COP failures

Two weeks ago, I replaced the #2 COP after it shorted out and blew the #30 fuse, left me stranded on the side of the road and a trip on a wrecker.
Yesterday I started getting a rough idle and a low rpm (idle to 2100) miss.
Today, my light came on. OBDII said it was the #2 again. I replaced it and the light is gone, but I can feel that it is idling a little rough. I cannot feel any mis above idle.

In the life of the truck (190,000), I think I am around 16 COPs being replaced. The first one went out around 700 miles. I am not sure what numbers, but #2 and #5 seem to be the recurring ones. I have used Motorcraft, Duralast and whatever the O'Reilly brand is. None seem to last.
Early on in the life of the truck, I had to replace the crank position sensor and that helped for a while.
Any ideas on why I am having this reoccurring problem.
Thank you.
 
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Old Nov 1, 2011 | 11:44 PM
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From: Utah
Do you get the engine wet allot? That could cause them to fail.. Cant really think of any other reason. Do you grease them up with dielectric grease? that might help..
 
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Old Nov 2, 2011 | 12:26 AM
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The only time it gets wet really is when it rains. Then it is just the water that splashes up from the road. The outages don't really seem to coincide with any rain storms.

I am putting DI-electric grease on the terminals and the plug connectors. I am also testing the resistance when they die and comparing it to a known good one. The bad ones show an open circuit. The boots don't have any signs of rust or other water signs on them.

I also replaced the spark plugs less than 10k miles ago with Motorcraft plugs.

Something else I just thought of that I have been meaning to mention for a while, in the mornings when I first start the truck, I have been hearing some weird mid to high pitched popping sounds lately. They last until just about the time the temperature gauge starts to move, then go away. Don't know if it is related or not, but maybe worth mentioning.
 

Last edited by BrianD; Nov 2, 2011 at 12:41 AM.
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Old Nov 2, 2011 | 05:40 AM
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From: ky.
Grease the boots not the connectors.
 
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Old Nov 2, 2011 | 05:19 PM
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From: MI
Originally Posted by BrianD
The only time it gets wet really is when it rains. Then it is just the water that splashes up from the road. The outages don't really seem to coincide with any rain storms.

I am putting DI-electric grease on the terminals and the plug connectors. I am also testing the resistance when they die and comparing it to a known good one. The bad ones show an open circuit. The boots don't have any signs of rust or other water signs on them.

I also replaced the spark plugs less than 10k miles ago with Motorcraft plugs.

Something else I just thought of that I have been meaning to mention for a while, in the mornings when I first start the truck, I have been hearing some weird mid to high pitched popping sounds lately. They last until just about the time the temperature gauge starts to move, then go away. Don't know if it is related or not, but maybe worth mentioning.
Yea, you have something going on with the electrical system. Somethings shorting or your getting disruption/disturbance from a chaffed wire.

The most common area in the harness that has to do with the ignition is above the AC accumulator. The harness sinks down making the connection and wires eventually bare,chaff, creating ignition havoc.
 
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