OopsIcrushedAprius

Hey all. A couple of us mechanics have been getting special tools sent to us from FMC to deal with "a possible injector issue" on the 2005 to 2007 5.4L engines. In 2005 there was a recall issued on the injectors for sticking open or closed. You would get a code reading "Misfire in Cyl. 2" or "Cyl. 6" It is very difficult to get the truck to throw a code, and even when it does, it is often temporary. Although you will get a miss and hesitation, the code nor the light will activate.

After changing coils, plugs, etc on many, many 2007 and 2008 trucks and still getting the same problem, we looked into it a little more. We noticed that the connector on the injector itself was wet when we unplugged it, and when we swabbed it with a Q-tip, it reeked of gasoline. For whatever reason the factory injectors are failing and allowing fuel to get into the plug seal. In a few cases, this also caused corrosion so bad on the tip of the spark plugs that the chrome dipped E3 plugs were actually peeling and flaking. It seems that FMC has not gotten "enough complaints to warrant a recall on the '07 and '08 injectors" which is strange since they DID issue a recall for the "05 for the SAME EXACT ISSUE!!

Long story short is, if you're getting this issue, report it to FMC customer satisfaction line. Then reference the '05 recall and when the person you are speaking with refers to their manual of what to say and what not to say, you just might end up getting reimbursed for replacing the injectors on one bank.
Don't let FMC screw us over...REPORT IT!