Originally Posted by Left Plate

Power train is 60k! If the CAC is not power train, then what other category does it fall under? It is not cosmetic, nor does it fall under a wear item!

Originally Posted by engineermike

A salesman once told me that power train is "anything oil lubricated".

Originally Posted by Left Plate

Power train is 60k! If the CAC is not power train, then what other category does it fall under? It is not cosmetic, nor does it fall under a wear item!

Originally Posted by TwinTurboFx4

I'm going to say bumper to bumper. Because a wheel bearing is a bumper to bumper item. And some transmission parts are bumper to bumper.

Originally Posted by TwinTurboFx4

All I'm saying is go get the TSB done if its COVERED under warranty. If you still have problems Get a full race cooler and a custom tune. Even if you worked in dealerships before I was in grade school doesn't mean you are a great mechanic.....

Originally Posted by Left Plate

This is the kind of input that I was looking for in the first place! Thanks!
I am just somewhat hesitant after seeing the picture of the new OEM CAC cross section that German EB posted on another thread?

Originally Posted by RAMJET

I have studied numerous posts on this issue. Some skeptic that moisture was the cause. I have experienced the severe engine misfire, bog on acceleration but have never had any warning lamp come on and never a stored or pending code in the computer. The bog was so bad at times I was stuck in the wrong lane trying to pass and could not. The bog will occur also after exiting the freeway and trying to pull out onto a secondary road which is really dangerous as it first accelerates then just
bogs and leaves you in the middle of the road.
I have driven the vehicle with a fuel pressure gauge to monitor fuel pressure and a scanner to verify that there was no issue with the electronic throttle control system. When the symptom occurred there was no malfunction recorded by the computer. There was no change in the throttle position, fuel pressure, intake air temp, engine temp, mass air flow did change but this was due to lower engine rpm. The oxygen sensors showed a rich condition - water entering the combustion chamber kills the combustion so raw fuel enters the exhaust.
To find out if moisture build up in the intercooler was really the cause
I cut a piece of cardboard to cover approx. 45 % of the intercooler and drove the vehicle for another month and tried to make the symptom occur under similar conditions. The symptom did not occur over a 4 week period. Before that it occured almost every week. After 7-8 weeks it has not occurred again.
I have noticed little if any power difference and no difference in fuel economy. The fuel economy has even increased slightly.
I do still experience the slight chuggle in 6th gear on light acceleration but this occurred before the modification.
I had planned to start reducing the size of the restriction until the symptom returned and then adjust the size to prevent the problem from returning.
I find it disturbing that as extensive as Ford claims to have tested this powerplant that they put it on the street without addressing this issue.
At some point during the testing it had to rain and these symptoms had to occur. It is also odd that it took them more than 2 years to figure out that a slight reduction in the intercooler capacity could correct it.
I guess I will trade my fancy cardboard for a plastic deflector and a pcm update. My experience showed me that this fix should have little if no impact on performance. My guess is that they are probably not deflecting air from as much of the intercooler as I have. The engine performs well with a pretty large amount of the intercooler covered.
I hope other owners will find this information helpful and my advice would be to have the deflector installed. If you still have the symptom you can always make it larger with a little cardboard and zip ties.