Finally got to 45 degrees here in Illinois so I was able to work on my truck in the driveway. I replaced cylinder #1 coil and injector with Motor Craft parts. I also replaced the fuel pump driver module (see picture). Just in case, I also had pigtails for the injector and coil but I didn't need them. It has only been a day but so far but the truck starts right up and runs very smooth.

 

Goooo!!! That looks like an archeological discovery!

 

Ha Ha,

I can't imagine that part would've lasted much longer. A good lesson not to mount dissimilar metals next to each other. I only thought of changing it because that part failure is well documented elsewhere on this forum.

 

rlawsha, I'm chasing a similar fishbite type misfire. No codes, and mode6 hardly ever shows a misfire except on startup. I've pretty much replaced all of the same bits that you have, except for the injectors. I did replace #7 injector after pulling the plugs a second time and found #7 to be wet. Plus mine is an '05 so I'm sensitive about the injector issue.

I'm still chasing the misfire though and my next place to look is the pump module. Did you ever have any starting issues? Stalling issues? Could you feel the misfire at any particular RPM? Park, neutral, drive? Were you stationary, moving?

I can feel my misfire in park and neutral at around 1500 rpm. It feels like a dead miss single cylinder. The truck starts, runs and drives fine. If I stomp on the gas I might get a little hiccup, but it will pull pretty hard without a miss through the load. I have similar dashboards on Torque Pro, for misfire, etc. I still need to use the PID that F150Torqued provided for Raw Fuel Rail Pressure and compare that to the other information.

 

I replaced all my injectors and coils and thinking back I should have waited until I could afford Motor Craft parts. I had just replaced all the injectors and coils and then I had a startup miss on cylinder #1. I put a new Motor Craft coil and injector on Cylinder #1 and it mad a huge difference. No more long crank on startup, it fires right up and sounds strong.

At the same time I replaced the fuel pump driver control module. I don't think that had anything to do with fixing the miss but unfortunately I changed the module, the coil and the injector at the same time so I don't know exactly what the problem was. I have a feeling it was the injector.

Torque Pro did show the misfires on cylinder #1 on startup so that led me to the solution. The coils were purchased form AutoZone and the injectors were purchased on eBay from Fuel Injector Man. I have a feeling if I ever get a windfall I should pull all injectors and coils and go with Motor Craft. For now I will just see how things go.

So to sum it up, it all started with a cylinder 4 misfire and along the way all this work was done:
Motor Craft Spark plugs
(Motor Craft timing chain job because Ford garage dropped spark plug piece into cylinder and had to remove head, might as well do chains once that happens)
Catalytic converters (130K miles and they were in bad shape - didn't help them running with misfires)
Injectors / coils (not motor Craft)
VCT Solenoids (Motor Craft)
Fuel pump driver module (I never did have stalling issue)
Fuel filter

Final fix (so far) replace #1 cylinder and coil (Motor Craft)
This fixed my intermittent long crank to start and cylinder #1 misfires.
Before I did all injectors and coils any vibration I noticed was at idle

 

Thanks for the reply. I was hoping the module was the end all, but maybe i'm wrong.

I bought my truck with a broken chain guide and codes for timing over retarded. I did a full timing job with Ford components, pulled the pan cleaned everything. Replaced rockers and lash adjusters. Buttoned it all up and it was quiet, but had a slight miss. I took it for a drive and it was hesitating and misfiring under load. That told me to change the plugs, so I did. Luckily they had been done before and the old plugs had anti-seize on them and none broke. After the plug change, I still had a miss. I used Motorcraft SP546 plugs purchased from amazon, but upon further investigation, they looked like SP515's repackaged. Those had a tendency to be bad right out of the box. Needless to say, I pulled those, replaced them with true SP546's from Autozone, but I still had a miss. I decided to replace all of the COP's with the Autozone Duralast parts, which worked on my Expedition a couple years ago. Still had a miss. All the while I had been monitoring O2 data streams and fuel trims via Forscan to try and isolate the issue. I did narrow it down to bank 2. When experiencing the miss, bank 2 O2 readings would drop lean because of the excess oxygen in the exhaust. I started pulling COP connectors to isolate a cylinder but it didn't really make much difference at idle. I decided to pull the plugs once more and clean any carbon that may be on the plug seats. I never had an issue removing or installing the plugs, but figured, I was pretty good at getting the plugs out at this point, it couldn't hurt. When I pulled the plugs, I found #7 was kind of wet. Fearing the worst, I decided to replace that injector with a Motorcraft replacement. No issues on install, but still the misfire persists. This is the point where I bought Torque Pro and a BT dongle and have been trying to chase down the miss. I only get an occasional misfire at startup which is common, but then I get nothing else. I can hold the idle at 1500 RPM and feel the miss but Mode6 never shows a thing. I have no codes, Bank 1 runs a little rich, Bank 2 runs slightly lean, but by slight I'm talking 3% which most people wont even bat an eye at.

I'm to the point of doing a compression test. For all I know, the first guy to do the plugs left a chunk in a cylinder and it cracked a valve. I don't want to throw more parts at it especially if it runs and drives fine, but just has a slight rough idle. I've run a couple quarts of Seafoam through the tank to help clean things out. I've seen my mileage increase from 14.7, 15.3, 15.8 to 16.1, so I know things are improving. Could it still be an injector issue, being that it's an '05? It's entirely possible.

 

Good luck and let us know what you find.