PSI-FX4

This will be a lengthy post, but I want to give the most accurate description as possible.

2002 Model - FX4 - 5.4L/Automatic
230,000 miles

Just want to say that this is my fathers work truck (bought new in 2002) and throughout its life has been maintained fairly well. Giving that at 230k miles is our first sign of trouble minus one alternator with any of our Ford Vehicles in our family, we are not upset by anymeans.

Transmission was serviced (flushed), spark plugs changed, and all coils checked at dealer at 110,000 miles about 3-4 years ago. Not a single problem, or symptom until today, and that's what has me a bit puzzled. Truck has had a Superchips Max Microtuner (87 Octane) installed since 30,000 miles, as well as an K&N intake sytem. I'm fairly mechanically inclined, and I pretty much know what to expect, but with all the codes showing up it's a curveball to me and I'm scratching my head to say the least not knowing where to start. My first instinct was a grounded plug/wire/harness or something. Nothing found (as of yet).

Here's what happened.
Father got in truck, and drove up town a couple miles and everything was perfect. He left it running and stopped at a friends house to pick up something. He got back in the truck, pulled out and everything was still fine. Stopped at a stop sign, and noticed that it almost died, and the O/D button was flashing (hadn't noticed it before), he tried to pull out and the truck just stumbles and will not move but just a few feet, and dies. He starts it back up, floors it and it moves enough to get rolling and finally limps himself to the house a couple miles away only being able to go 20-30mph max. Thankfully it was all down hill (literally) to the house.
Symptoms:
Truck idles perfect in park. Revv it up quick and it stumbles, then revvs. Put the truck in gear and it struggles to stay idling and wants to die. Try to pull out, it's not happening. We had to put it in 4x4 Low-Range to get it to crawl over to my garage to get it up on the lift. Now.... I start checking fuses, wires, and everything.... everything comes up empty. Check Engine Light was obviously on, and he said it had come on about a week before (he usually tells me when it comes on) and the only codes before this was a lean O2 bank code (can't remember number), nothing too major. I reset it before and it rarely comes back. I hook up the superchips tuner to pull the codes.... here is where the fun begins......

P0135 - Oxy Sensor Heater Circuit (bank 1, sensor 1)
P0155 - Heated Oxy Sensor Heater Circuit (bank 2, sensor 1)
P0403 - Exhaust Gas Recirculation Circuit Error
P0443 - Evap Emission Ctrl Sys Purge Ctrl Valve Circ Error
P0740 - Torque Converter Clutch Circuit Malfunction
P0743 - Torque Converter Clutch Sys Electrical Failure
P0755 - Shift Solenoid B Error
P0758 - Shift Solenoid B Electrical
P1451 - Evap Emission Ctrl System Vent Ctrl Circuit
P1460 - Wide Open Throttle A/C Cutout Circuit
P1747 - EPC Solenoid Short Circuit
P1760 - EPC Solenoid Short Intermittent


WTF is going on!? LOL!

Trans shot? Everything went down at once, and might as well haul it to the junk yard? Any help pointing me in the right direction is MUCH appreciated!

And yes, I have searched pretty much every one of these codes for about 3-4 hours this evening and have came up with my own theory of problems, but I still honestly don't know. Any Ford Tech's out there that would like to chime in? Thanks!!

biglee88

Find out what they all have in common. the Trans and o2 sensors may be related cause I'm sure they are all on the same harness ( not possitive ). But I'd look for a wiring issue by the Trans that's my best idea it sounds like wiring to me. Maybe they all share the same ground more then likely the do

PSI-FX4

I've searched and searched and haven't been able to find any grounded wire/harness. Would it be possible that a ground has rusted into that all these are tied too and cause this to happen?

Frank_Ford

I believe a lot of the codes you are experiencing are because of the problem in running as you described. I would check out the fuel system to start as it really sounds like you might be starving for fuel.

2003XLT

first off if you clear the light do the codes come back immediately? also if you have live feed on your scan tool clear the codes start the truck and let it run (If necessary drive it) until the service engine light comes on. the codes are all linked. I wouldn't worry about the trans codes. it sounds like maybe the truck was bucking due to lack of power and that triggered all the tranny codes. I doubt that's a fuel delivery problem considering you have fault codes in both banks you need to hook that truck up to a scan tool that can pull up a freeze frame data log and that will tell you everything you need to know about truck speed OSS speed torque converter level and the most important is to find out what code triggered first because that first code is gonna be your problem

PSI-FX4

I reset the codes and they all come back within a minute of the truck running. I only have my Superchips maxx microtuner that I'm using for my scan tool. I'll try and run through all the bases and see what I come up with. I'll see if any of my friends have another scanner.

akdoggie

The last time I saw 12 codes set at once in this function was a common ground where these items all attach. It had corroded so bad that none of the wire attached had a ground side.

I agree with 2003XL about clearing the codes and seeing if they come right back. If you have a ground problem, they will come right back immediately.

2003XLT

I'd say you were right but Evap codes were also triggered so unless the egr, o2 sensor, converter, all share the same ground I don't think that's it

akdoggie

There is a common ground for the sensors and GEM @G200. It is near the main wiring harness on the left side. I show it marked at the lower cowl panel. An awful lot of items are tied into that ground connector according to the service manual. Most of the dash gauges, antilock, antitheft module and many others all go to one ground, G200.

Personally, it's all a guess right now. But to set 12 codes over and over, mostlikely means a ground problem somewhere. There has to be one common denominator. The only one i can see in the wiring is the ground at the G200 address.

Just another thought. How about checking the battery negative terminal and seeing if it is corroded. I could be as simple as a bad ground at the terminals. If you think it might be a ground problemm you might also add another ground strap to the body and see if this cures the problems.

PSI-FX4

Battery is terribly corroded. I will clean both off, although it has no trouble starting. I have added a 4awg additional ground from the battery to the body to help with some grounding issues I've read about back when I drove this same truck back in high school, i also had a sound system and that was the need for the additional ground. I will clean the battery, check the g200 ground and reset the codes.