Cliff notes fix for those with CAC problems: apply pressure to right peddle! I like that fix.

 

Had my CAC replaced today along with the reflash. For the moment it does seem like the 55mph uphill shudder might be gone, but we'll see after the relearn-honeymoon period. It took just under 2 hours for the tech to perform.

 

I have 17000 miles on mine in the same weather as you and have never experienced any issues whatsoever(knock on wood)I just find it really odd that one will do it and another doesnt.

 

stock intercooler is mounted low, so the charge piping and inlets are in the middle of it:




Our Full-Race intercooler is mounted in the grille, so the charge piping and inlets are under it:













perhaps he goes on longer distance 'low throttle" trips, while you mash the long-skinny-pedal around town? Maybe you haul stuff in the bed and put more load on the motor than he does? Every application is different and every owner's driving habits are unique

I do not know the exact difference, i can ask. I believe the new updated CAC may be thicker with more of the top rows blocked off from thru flow - but do not know for certain.

 

Wow! What a read.

 

First, a big thanks to you Goeff for pursuing this with the people at the PRI show. I agree with your explanation of the problem. I don't understand Fords solutions. I'll list my comments and concerns below.

There seems to be no question that water is accumulating in the CAC. Its just simple physics that water condenses out of compressed air. The more humid it is the more water accumulates. (It's just like your air compressor in your shop at home. After using it a while water accumulates and you have to drain it out.) So the fix isn't about preventing water from forming, it has to deal with getting rid of the water.

I think it may be more dramatic. Think of your shop vac picking up water. The increased air flow can suck up the water that has accumulated in end tanks. One individual in the forums thinks he may have nearly hydrauliced his engine and bent a connecting rod! I think he eventually got so frustrated he got rid of the truck.

I have been waiting for a TSB that is a better solution. Maybe I better take what little fix we have and get the TSB done.

I don't understand how blocking off the top rows makes the bottom rows warmer. It is only logical that the top would get warmer and the bottom would stay cool because it still has the air flow. I think the flap in the TSB is put on the top because it is very easy to install it without removing the CAC. Just fasten it on with a couple of Christmas tree pins like Ford is doing. So Ford did what was easiest not what is best.

I haven't had the TSB applied, but I did block off the bottom of the CAC. I used a piece of corroplast (plastic corrugated board). I went for an easy cruise at 60 mph, than stopped and checked the temp of the CAC to see if was getting hot. It wasn't even warm! I think we need more than a flap to stop the water from collecting.

Geoff, when I have the TSB work done, would you recommend I have the spark plugs pulled and regapped to 0.030? I don't think it is part of the TSB.

Your design looks dramatically better! I think you could still collect water in the CAC outlet tube, but it is a longer horizontal run, with the air flow directly over it, so it would more easily evaporate any accumulated water. Are you testing your new CAC design on an otherwise stock engine?

I think the present TSB's are bandaids. They reduce the magnitude and frequency of the problem, but they don't totally eliminate it. The water is collecting from the compressed air and that can't be changed. Ford needs to do something to get rid of the water, either drain it off before to much collects or do something innovative, like using an ultrasonic transducer in a water trap to breakup and atomize the water before it collects to a damaging level. Ford you have my permission to use that idea free or charge.

I hope the Ford techs and engineers are reading this discussion. Ford fix this so I can start enjoying my otherwise great truck.

 

I would like to know the difference also. If someone could explain to me how the new CAC solves the problem I would be happy.

 

The turbo compresses air and that makes heat.
The CAC removes that heat and reduces the air temp back down close to ambient air temp.
The stock CAC is very efficient so by blocking a portion of the CAC (the hotter top section is better) you raise the overall temp in the CAC to a point that it falls outside of the dew point - air temp range that is causing condensation.
Reducing the efficiency of the CAC to raise it's internal temp in cool conditions.

This leads to a trade off in hot weather. You will lose some power on hot days or will need to run premium fuel to maintain power while towing etc at lower ambient temperatures than you did before the fix.

Electronically controlled flaps like on the Focus would be the best answer. Closed when cold, open when hot, programmed for maximum performance and reliability.

 

Man I would be concerned with that new inter cooler design in the pic it blocks the rad almost completely would definitely cut down on the cool air that the rad needs especially when towing hmmmm be careful on a warranty claim with that blocker on there!!

 

I'm still waiting on the new CAC for my truck. I don't know what the actual differences really are, but can relay what I was told. Please keep in mind that I'm not an engine expert and have no way to verify any of this. Ford may have just been making the whole thing up to keep me quiet.

From what I've been told, Ford has done extensive testing of this problem and have been able to reliably recreate the issue inside of a wind tunnel given the proper environmental variables. They believe the problem occurs on the F150 but not on other ecoboosts because of the size and placement of the CAC. When the problem occurs it is typically accompanied by a misfire on bank 2 cylinders. Bank 1 is not as likely to be affected because just after the throttle body the intake makes a slight turn towards the passenger side. This turn causes the majority of the moisture (being denser than the air it is with) over into the bank 2 side of the intake. The misfires create a significant loss of power and the resulting incomplete combustion that occurs can damage the bank 2 catalytic converter.

The newly redesigned CAC has had changes made to it's internal airflow. It's designed to keep the air moving quickly through the CAC. The faster moving air helps to prevent moisture from collecting on the internal surfaces of the CAC and instead be continuously pulled into the engine. This allows the engine to continually ingest the moisture in smaller, more manageable amounts. In Ford's controlled wind tunnel testing the new CAC has been effective at preventing the problem from reoccurring. The new CAC is slightly more restrictive than the older version, but there is no difference in engine power. However, the turbos may have to work just a little bit harder to achieve the same pressure at the intake.