Intermittent Stumble and/or Misfire on Hard Acceleration – DTCs P0304, P0305, P0306, or P0430 – 2011-2012 Ford F-150

TSB 13-8-1	3.5L GTDI – INTERMITTENT STUMBLE/MISFIRE ON ACCELERATION FROM HIGHWAY CRUISE IN HUMID OR DAMP CONDITIONS WITH POSSIBLE DTC P0304, P0305, P0306, OR P0430
Publication Date: August 5, 2013

 

FORD:

2011-2012 F-150

 

This article supersedes TSB 13-3-3 to update the Service Procedure and Part List.

 

ISSUE:

Some 2011-2012 F-150 equipped with a 3.5L gasoline turbocharged direct injection (GTDI) Ecoboost engine may exhibit an intermittent stumble and/or misfire on hard acceleration after an extended drive at highway speeds during high humidity or damp conditions. This may result in either a steady or flashing malfunction indicator lamp (MIL). Diagnostic trouble codes (DTCs) P0304, P0305, P0306, or P0430 may also be present. Evidence of misfire may be available in Misfire Freeze Frame Data even with no active DTCs.

 

ACTION:

Follow the Service Procedure steps to correct the condition.

 

SERVICE PROCEDURE

1. Acquire Misfire Freeze Frame Data and DTCs with the Integrated Diagnostic System (IDS) service tool. Use the following steps with IDS to obtain Misfire Freeze Frame Data.
   1. Select Toolbox
   2. Then Data Logger
   3. Then Modules
   4. Then PCM
   5. Next, select the following PIDs: MFF_LOAD and MFF_RPM.
2. Is the misfire concern only repeatable in humid or damp conditions?
   1. Yes – Proceed to Step 3.
   2. No – This article does not apply. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) Manual Section 3: Powertrain Symptom Index to inspect such areas as Ignition, Compression, and Injection.
3. Does the Misfire Freeze Frame Data indicate engine speed above 2500 rpm and load 100% or above? (Figure 1)
   Figure 1 – Article 13-8-1
   1. Yes – Proceed to Step 4.
   2. No – This article does not apply. Refer to PC/ED Manual Section 3: Powertrain Symptom Index to inspect such areas as Ignition, Compression, and Injection.
4. Is vehicle equipped with latest level charge air cooler, engineering part number BL34-9L440-AE? (Figure 2)
   
   Figure 2 – Article 13-8-1
   1. Yes – This article does not apply. Refer to PC/ED Manual Section 3: Powertrain Symptom Index to inspect such areas as Ignition, Compression, and Injection.
   2. No – Proceed to Step 5.

 

NOTE:

CARE NEEDS TO BE TAKEN NOT TO INSTALL THE REVISED BOTTOM AIR DEFLECTOR ONTO CHARGE AIR COOLER ENGINEERING PART BL34-9L440-AE AS IT WILL RESULT IN HIGHER MANIFOLD AIR CHARGE TEMPERATURES AND SIGNIFICANT LOSS OF ENGINE PERFORMANCE.

5. Is DTC P0430 present?
   1. Yes – replace the left hand catalytic converter. Refer to Workshop Manual (WSM), Section 309-00. Proceed to Step 6.
   2. No – Proceed to Step 6.
6. Is the Charge Air Cooler equipped with the top air deflector? (Figure 3)
   Figure 3 – Article 13-8-1
   1. Yes – remove and discard. Refer to WSM, Section 303-12. Proceed to Step 7.
   2. No – Proceed to Step 7.
7. Install revised bottom air deflector.
   1. Make sure that the lower forward facing bottom seven (7) tubes and eight (8) rows of fins on the Charge Air Cooler are dry and free of dirt and debris. (Figure 4)
      Figure 4 – Article 13-8-1
   2. Clean the charge air cooler lower forward facing bottom seven (7) tubes and eight (8) rows of fins by wiping surface down with isopropyl alcohol.
   3. Peel the protective tape off the adhesive side of the deflector.
   4. Install the deflector onto the charge air cooler core surface insuring the forward facing bottom seven (7) tubes and eight (8) rows of fins are covered and pressing firmly into place by hand maintain even pressure for 30 seconds. (Figure 5)
      Figure 5 – Article 13-8-1
8. Reprogram the PCM to the latest calibration level using IDS release 79.02A or higher. This new calibration is not included in the 2012.5 DVD. Calibration files may also be obtained at www.motorcraft.com.

 

NOTE:

PLEASE ADVISE THE CUSTOMER THAT THIS VEHICLE IS EQUIPPED WITH AN ADAPTIVE TRANSMISSION SHIFT STRATEGY WHICH ALLOWS THE VEHICLE’S COMPUTER TO LEARN THE TRANSMISSION’S UNIQUE PARAMETERS AND IMPROVE SHIFT QUALITY. WHEN THE ADAPTIVE STRATEGY IS RESET, THE COMPUTER WILL BEGIN A RE-LEARNING PROCESS. THIS RE-LEARNING PROCESS MAY RESULT IN FIRMER THAN NORMAL UPSHIFTS AND DOWNSHIFTS FOR SEVERAL DAYS.

 

Obtain Part Locally

Isopropyl Alcohol

 

PART NUMBER	PART NAME
BL3Z-5E212-E	Catalytic Converter Assembly
W520514-S440	Nuts (2 Req)
DL3Z-2021702-A	Air Deflector
W711281-S300	Push Pin (2 Req)

 

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

OPERATION	DESCRIPTION	TIME
130801A	2011-2012 F-150 3.5L GTDI: Diagnose And Inspect The Charge Air Cooler, Install Revised Bottom Air Deflector And Reprogram The PCM Includes Time To Remove Top Air Deflector If Equipped And Clear DTCs (Do Not Use With Any Other Labor Operations)	0.5
130801B	2011-2012 F-150 3.5L GTDI: Diagnose And Inspect The Charge Air Cooler, Replace The Left Hand Catalytic Convertor, Install Revised Bottom Air Deflector And Reprogram The PCM Includes Time To Remove Top Air Deflector If Equipped And Clear DTCs (Do Not Use With Any Other Labor Operations)	1.0

 

DEALER CODING

BASIC PART NO.	CONDITION CODE
6K775	42

 

 

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Service Information & Reprogramming

Software necessary to program electronic modules to the latest calibration level, perform module initialization (PATS), and set Programmable Parameters on Ford, Lincoln and Mercury vehicles.

Ford Module Programming (FMP) is a software application that allows subscribers to program electronic modules on Ford, Lincoln and Mercury vehicles. It can be used for:

• Reprogramming emission-related (OBDII) modules on some vehicles manufactured in 1995 and all vehicles manufactured from 1996 to the present
• Reprogramming or reconfiguring non-emission-related modules on many vehicles (UBP and MS-CAN not supported)

In addition, module initialization (PATS) functions such as Keycode Erase/Reprogram and PCM Parameter Reset can be done using this application.

J2534 Device using Ford Module Programming (FMP) can Reprogram and Configure most Modules.

Latest Calibration Information

Module Build Data (As-Built)
Use VIN to obtain As-Built data

www.motorcraftservice.com