2010 Ford Expedition ignition oddities.

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Came in on a hook with a no start complaint....
Had Coil Primary Circuit codes for all 8 coils, Checked for voltage at a couple coils.....None found.
Found the 15amp Ignition Coils Fuse blown along with evidence that the circuit had been under some continuous stress as the plastic portion of the fuse was a little melted.

Installing a new fuse got the truck running, Idled just fine. Test drive revealed it's barely driveable....REALLY bad misfires. I didn't want to get stranded so I turned around.

I used a Low Amp Clamp at the fuse connected to my Vantage Pro, Average Amp draw was right around 10amps, With the "Multi Strike" coil firing at idle that Fords use makes it a little hard/impossible to accurately average the continuous current draw. But what I saw looked pretty extreme from a current standpoint BUT the waveforms/patterns looked uniform!!

I started leaning toward a bad connection/low voltage condition in the Coils power circuit, I whipped out my trusty Halogen headlamp bulb & load tested the circuit at all eight coil connectors.......Nice & bright!!

OK.....My thought process.
*I'm not dealing with shorted coil/s as the waveforms looked uniform.
*Eight separate PCM driver/transistor issues......Not hardly a chance in Hades!
*Eight degraded coils or all eight are leaking secondary voltage? That seemed far fetched.
*Spark Plug erosion....Vehicle has 96,000 miles & I doubted platinum plugs could erode that much given the normal service table calls for plugs at 90,000.

I decided the easiest thing was to pull some plugs, Sure enough they were in VERY bad shape with a gap you could drive a bus through!
Eight Motorcraft Coils & Plugs fixed the misfires.
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I wonder how bad it ran and for how long.

Single digit mpg for a long time is my guess.
 
Nice work!

Is the new plug a different heat range? The porcelain insulator appears to be longer. (But that might be an optical illusion due to the worn centre electrode.) The gap on the new plug is what, 0.044" or so? That puts the old one at around 0.15"? Ouch!
 
Makes me wonder if the mileage has been somehow altered and it has wayyyy more than 96k on it. Either that or the platinum tips were damaged before install, perhaps hamfisted gap checking.
 
I usually recommend doing them to customers at around 60k they usually are worn wel below spec by then. Also common for the porcelain to develop cracks in it causing the spark to arc through coil boot to cylinder head. Complain will usually be bucking on hard acceleration for that.

The 3v engines tend to be hard on spark plugs.
 
How many of them broke coming out of the head?


Bet it runs like a new truck!

My old 130K mile 2 valve 5.4 got 8 new coils last year. I could swear it picked up a bunch of power from it. I was running a mix of 17 year old coils and junkyard random coils. Put a set of OE coils in and it ran like new.
 
I've always changed my plugs ahead of schedule. My current vehicle says to change them at 192,000km (120K Miles) and I will be doing them far before that. An ounce of prevention is worth a pound in cure. How much did the hook and diagnoses cost this customer?
wink.gif
 
Originally Posted by Miller88
How many of them broke coming out of the head?


Bet it runs like a new truck!

My old 130K mile 2 valve 5.4 got 8 new coils last year. I could swear it picked up a bunch of power from it. I was running a mix of 17 year old coils and junkyard random coils. Put a set of OE coils in and it ran like new.



Those don't break. Late 07/early 08 they changed the heads to use a more conventional plug.
 
I think i will continue to change plugs a bit early and continue to under gap them by about .005 !
 
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Originally Posted by CT8
You are the master. ! The basics .

It's was kinda humbling honestly.....The blown fuse threw me off my game!

Originally Posted by Trav
Funny we were talking about wide gap and coil stress a few days ago in a thread. You just proved it.

It's very interesting that it was drawing that much current on the primary power supply. Something I don't ever recall seeing. I guess if the power supply was split with 1 fuse per bank.....It wouldn't have blown a fuse & sent me down the Amp draw rabbit hole.


Originally Posted by Nick1994
I wonder how bad it ran and for how long.

Single digit mpg for a long time is my guess.

Surely it ran really bad before just dying on the customer, There was nothing on the work order about driveability concerns.
I'm not a behavioral specialist, So.....I have no idea why customers don't communicate better when it come to issues with their vehicles??

Ford & their misfire monitor might have something to do with it, This particular vehicle had one of the most passive monitors I have ever seen (Even for Ford standards)
#5 cylinder counted up to 140 misfires in Mode $06, The rest were at zero counts. Trying to get the truck back to the shop had to have been 200,000 misfire events spread out between all the cylinders.

Before someone asks......The codes hadn't been cleared in over 30,000 miles. It should of had a P0300 set in memory & the SES lamp illuminated.....Flashing even.
 
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I heard somewhere it's 60,000 misfires in a row on any single cylinder to get it to set a code. I blew a coil a few years back and didn't have any choice but to drive it 100 miles with a dead cylinder. Never set a code.
 
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