engineermike

Nothing new here, just an up-to-date compilation/discussion of all the "fixes" for the Ecoboost shudder issue reportedly caused by condensation.

1. Ford TSB's. Some combination of reducing the intercooler effectiveness and re-flashing the ECM. It seems to work (or at least reduce the frequency) for some and not work for others. However, some report a loss of power/response and/or fuel mileage.
https://www.f150forum.com/f70/there-...cooler-156900/
https://www.f150forum.com/f70/new-tsb-13-8-1-a-221455/

2. Cold-air intakes. Some experts theorize that the factory air intake pulls water mist in with the air coming from the inner fender. Many aftermarket air intakes pull from under the hood, so they should pull in less mist.

3. Aftermarket intercoolers. Changes the location/volume of the place where condensation pools, and perhaps improves air flow distribution. Seems to work for many, but not for some. Wagner and Full-Race currently offer this upgrade, with rumors Garrett has one coming.
https://www.f150forum.com/f70/defini...thread-208585/
https://www.f150forum.com/f70/codens...cooler-216830/
https://www.f150forum.com/f70/ecoboo...ermany-170867/

4. Intercooler weep hole. Drilling a small (.050-.060") hole in the bottom driver's side of the intercooler. About half a dozen have done this with a high rate of success, plus the price and effort are right. Volvo did this on many of their intercoolers, plus the Chevy Cobalt has an intercooler condensate "trap" which operates on the same principle.
https://www.f150forum.com/f70/ecoboo...s-here-223824/

5. Spark plug gap. Lots of trucks have been found with spark plug gaps way over spec, particularly early production models. Re-gapping down to ~.030" has fixed many of them. Stronger spark can reduce mis-fires, even if they're caused by water.
https://www.f150forum.com/f70/eco-sp...ug-gap-169457/

6. Custom tuning. Though it hasn't been widely reported to fix the problem, every TSB by Ford includes a reflash, so there must be something there. It also stands to reason that the conditions that cause condensation can be changed using tuning. No tuner has released a tune specifically to address the issue, but my theory is that either better (5 Star) or worse (Ford TSB) spool-up response could improve the situation. Better response can get you into boost more frequently, which could clear condensate. Slower response could lower intercooler pressure at cruise, reducing the formation of condensate.

7. Driving habits. Yes, I know you shouldn't have to change your driving habits to keep your intercooler happy. . . but it could be fun. Be sure to get into boost for 5 or 10 seconds periodically to heat up the intercooler and blow out any pooling moisture. You could also move to a drier climate.

8. Intercooler shroud. This would be a home-made device to block air flow over the intercooler, just like the TSB. The advantage would be that you can get the reduced intercooler effectiveness, without the potentially power-robbing reflash. I don't believe anyone has done this one, probably because most think it's ridiculous to reduce intercooling.

9. Upgraded turbos. The theory is that the stock, quick-spooling turbos build pressure in the intercooler at cruise, which allows condensation to form. Larger turbo/turbos should build less intercooler pressure at cruise, which would reduce condensate buildup. Also, note that Ford increased the turbo size in the 2013's, MAYBE to help with the issue. At least 4 companies are working on this upgrade now, including Full-Race, Morkin Design, Precision Turbo, and Ecoboost Power Parts.
https://www.f150forum.com/f70/upgrad...9-20-a-224772/
https://www.f150forum.com/f70/defini...thread-208585/
https://www.f150forum.com/f70/vtx-56...k-tune-220714/

I'm thinking that if you do most of the above (particularly #4 and 5), the problem could be totally solved. FWIW, I have an Injen intake, 5 Star tuning, the weep hole, and the driving habits and I don't have the problem, though I never really had it to begin with.

Further comments?

Mike

brucesears

I think you're right Mike, especially with 4,5,6. I had 1 'episode' before I regapped the plugs and drilled a tiny intercooler weep hole and none afterward. And we have had an extremely humid spring and summer so plenty of chances to do so. And with SoCal tuning you get into boost quite a bit with no decrease in gas mileage(usually increases).

MadocHandyman

These are my observations so far in 52000 km

Never had the loss of power, only light shudder going up hills.
I'm a bit aggressive on the go pedal most of the time.
Gapped plugs - improved quite a bit but still there on occasion
Higher grade fuel - helps even more (ethanol?)
Had the TSB, CAC change and plate installed. Seemed to help but still felt occasionally.
Did the weep hole a week ago. Not much time or mileage with it yet but so far so good.

And a big thanks for putting these threads together engineermike!

SkiSmuggs

Very nice summary of the issue and solutions, Mike. I even suggested to the Ford rep here that Ford should look at more than just the IC. Nice job!

Left Plate

Nice write up Mike!
IMO the tune is the first step (but not the whole cure as mine fell down with a tune, but not as severe as stock) and the spark plugs go hand in hand w/that!
After that it would be aftermarket IC or drill a hole if that is working?
And top it off with an aftermarket CAI for good measure.

Jaythor74

Thanks for the great write up. As discussed on this and other threads the weep hole seems to be working. I can't figure out the down side of a small hole in the CAC. The next question is if it works why would ford not come up with a similar solution ? It must have cost ford a fortune to replace so many intercoolers by now.

EcoPowerParts

I'll be happy to shudder proof your Ecoboost with a new intercooler and turbo set starting 9/20!

I would also suggest going ahead and drilling the hole in the new intercooler when it arrives, wouldn't hurt anything. Worst case scenario move to Phoenix, NO condensation here...

Justus

This is a great reference combination...thanks!

Gmc350

EPA rules wouldn't allow it to be vented or spewed to atmosphere

NASSTY

What they don't know won't hurt them.