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2005 Expedition: 40mph shudder, low mpg, stall

Discussion in '2nd Gen - 2003 - 2006' started by booksix, Jun 30, 2020.

  1. booksix

    booksix New Member

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    I've had a few issues pop up lately - going to try to explain in chronological order. Things to know: The truck runs amazingly well (smooth and powerful), trans shifts great, no real issues. 230k on the odometer. 4R75e, 4wd, towing package. Plugs 50k ago, Trans-pan fluid and filter 50k ago.

    Basically, about 2 or 3 weeks ago I started noticing a small "rumble strip" shudder around 40mph (low rpm, low throttle, high load - just bordering on the 4-to-3 downshift). It's easy enough to avoid, just don't linger in that "keeping it from downshifting throttle position" as it is gone as soon as the trans shifts. This really only happened when loaded down with the band and our gear (I'm a touring country artist) or when pulling a trailer, but it happens every now and then when it's just me and I'm going up a hill or something. So of course I check mode 06 and find #4 has about 30 misfires registered. I pull the coil, clean the terminal and spring (corrosion), apply dielectric and reinstall. It's been a week and a decent amount of driving - no more mode 06 misfires on any cylinder (this never triggered a MIL at all). Thought this fixed the shudder until I had a truck with some cargo weight and it was back.

    Next tried shudder fixx just to see if it'd calm the shudder down, as I was still wondering if it was the TC/trans or if it was the COPS/Plugs (again, plugs are 50k old... all but one COP are unknown mileage - up to 230k in theory). Shudder fix didn't seem to affect it. Still, no MIL or Mode 06 so I'm not leaning toward misfire... but I don't know much about mode 06 and how accurately it catches EVERY misfire...?

    Ok, today I was backing out of a parking spot. When I braked to stop and shift into D the truck stalled. Nothing violent - in fact, I had to look at the tach to know what happened (to be fair, the A/C fans were up a couple notches so I couldn't hear the engine). Weird. Restart and for a few minutes it's kind of weird but seems to go back to normal.

    Now, I'm taking off from lights and thinking the acceleration is off. Like I'm lacking a bit of power, even though the engine is running like a top... so maybe TC slipping. Maybe in my head, maybe not.... hard to say.

    One other thing to note: about a week ago I had two single instances of a P2135 (throttle a/b mismatch), accompanied by "engine failsafe mode" that would go away after cycling the key. I've driven 6-7 hours since (trying to trigger it so i could better diagnose) and it hasn't returned. Possibly a fluke due to a shot battery (since replaced) and horribly corroded terminals. As of now I feel it is unrelated to the trans issues.
     
    Last edited: Jul 1, 2020 at 1:55 AM
  2. Jb14

    Jb14 Full Access Members

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    Hi Booksix sounds like you have few gremlins and not sure I can answer all or any. I will just express my experience in regards to #4 misfire. Not sure if I had the same issue but I was experiencing an issue where the truck would start to feel off and somewhat cut out. Took to a mechanic and the #4 COP went bad. This happened a couple of times only to #4. I discovered an inconsistent coolant leak from the plastic connector on the firewall dripping on the #4 COP that created the intermittent issue.

    I bought my 05 used in 2009 with 32k miles and had an odd issue where I would be driving no issue then it would be as if my trans was put in neutral. Engine running and would just rev. I would pullover turn the engine on and off and everything would be fine. That happened over a year and a half time period with about 60 to 70k miles on the truck, and then went away (I have 292k on truck) I mention this because at the I did research and found that was an issue that needed a software update from ford (I never did) The only other thing I could say is make sure your MAF is clean and that you have changed your inline fuel filter that is under the truck on the driver's side passenger door (need special "cheap" tool to remove)

    Also when pulling be sure not to be in overdrive as OD will pop

    Good luck
     
  3. riphip

    riphip Full Access Members

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    Also check your vacuum lines for leaks. These are the more simple fixes.
     
  4. wacoexpy

    wacoexpy Member

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    Had the whole 40MPG shudder at low RPM under load. It felt like a transmission issue, but it wasn't in my case. I wound up replacing all of my plugs and coils and the problem went away. The plugs only had 50K on them at the time. I also had there throttle body error failing into failsafe mode just like you. I replaced the throttle body and the shudder at 40 MPH continued. I had to replace the plugs and coils to make that issue go away.
     
  5. Frank Swygert

    Frank Swygert Active Member

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    With 230K on it with the original coils, I'd just replace the other seven coils. When replacing the plugs did the piece between the plug and coil get replaced? Don't recall what they are called, but the mechanic that replaced my plugs told me he always replaced those when replacing plugs as they caused trouble, not the coil itself. When you replace a coil I think that part comes with the replacement coils, not sure.

    I do a lot of my own maintenance, but replacing the plugs on this thing (2005 Expy) is something I passed on. Took one look under the hood -- could get to three plugs easy, another two with a little work, lots of stuff to move out of the way for the others. Then there was the chance of breaking a couple off. Paid the $600 to have it done. Really ticked me off that Ford has no better engineers than this! I changed the COP units on my 2003 Tundra with no issues. The back two are a little hard to reach, but accessible without moving a bunch of stuff around. I don't mind things like having to remove the dash to get to a heater core -- that's usually a 10 year or so job. Spark plugs, even 100K plugs, should be easy to get to!! I just hope I have no issues before I get to 200K and they should be changed again.
     
  6. Wegner44

    Wegner44 Well-Known Member

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    Just curious on the engine you have. I know the 3 valve's had an issue with the cam phaser's right around that year. Just a shot in the dark, but something to consider having checked before just throwing money at it. Hope you figure it out!
     

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