Once again...plugged cats? Maybe?

[piotrsko]

My ranger has had problems with connector corrosion typically on the fender series driver side and the ones going to the PCM itself. However, the corrosion could be anywhere. I am also having general harness problems. When I swap out the PCM for the spare, it learns the engine then after a while it goes back to it's old funny running.

 

[techsvcs]

i didn't seem to see anywhere where you said you changed the ignition module but mine was doing the same thing and that fixed it up at the time.

 

[Spitfire1975]

i didn't seem to see anywhere where you said you changed the ignition module but mine was doing the same thing and that fixed it up at the time.

whoops. My bad. ICM has been changed with a new one. I went and edited the list.

 

[Bulldozer]

Spitfire you say "EGR system (all of it)" but did you clean the port leading to the air intake from the EGR, behind the Throttle body? I've been following your thread here as I have what sounds familiar to your problem.
I took off the EGR to find the port leading into the Upper air intake was blocked SOLID! At the EGR end and into the EGR was a mass of slimey goo. About an inch in the goo turned to hard carbon and futher into the mass(2") was solid carbon. I'll attempt to add a picture.
I also ended up replacing the EGR with new as it was in no way cleanable. I put a vacuum to the old EGR and could see very little movement compared to a new one so it was replaced.
The upper air intake on my truck was black inside.

I have started with a can of intake manifold cleaner. The type you use whilst the engine is running. Reving up the engine and spraying directly into the Upper air intake. By my second can of intake cleaner I noticed a huge difference. I was spinning my tires from a stand still,(not my norm). Also added a double dose of Lucas Injector cleaner to the fuel tank.
On a daily basis I'm getting better performance.

Just a note... I spoke with a Ford mechanic.
When he looked at my truck first thing he said was,
Spark plug wires
Clean the Throttle body and intake good.
replace EGR
replace Air Bypass Valve Assembly
Fuel pressure check should be 30 - 40psi
(Fuel pressure on my truck at key on= 40psi, Engine running @ 36psi)

I live in the Pacific Northwet (west)
The 2.9, (especially the early 2.9s) had a common problem with the fuel rails rusting from the inside, very much like the cheap portable BBQ burners. Look at the fuel rail and look at a cheap BBQ burner, now tap the rail...

Like I said earlier in this post I'll try to post a picture of my EGR, but being a noob may not be able too.

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Hey I wanna thank everyone for helping Spitfire here it gave me a place to start my search. This and other posts...

 

[techsvcs]

Man Bulldozer that was an dejavu post for me cause that is exactly what my egr looked like and i mean from the light brown that looks like water and oil mix to the thick black carbon and it took me alot of picking and cleaning to get my port cleaned! What about the tube leading to the exhaust manifold was it clogged cause i didn't check mine?

 

[Spitfire1975]

Bulldozer......

Yes on all counts. My port was not clogged with any gel, however. It was only clogged with carbon. When I put this engine in the truck ( about 6,000 miles ago) I cleaned and checked the rail and the injectors. All seemed to be in good condition.

I think I am going to start replacing the few remaining used sensors with new ones. The IAC, the knock sensor, the MAP sensor and the air temperature sensor.

 

[Bulldozer]

What about the tube leading to the exhaust manifold was it clogged cause i didn't check mine?

I got in there and blew as hard hard as I could, it was free of clogs. For this reason I didn't spray any cleaner down this tube. Didn't want to load the exhaust with raw explosive cleaner either.

Yesterdays drive about was fairly good. I don't have many places around to get up to speed so I was running around in 3rd gear(automatic) keeping the O.D. out of the picture. I am now into my 3rd can of intake cleaner.
Last week I was running 95% of the time very bad, with the occasional good spurt. Now I'm running 95% good with the occasional bad spurt. When running normal I can have my cuppa coffee sitting on top of the intake with out spillage.

I stopped in to pick-up another can of cleaner, when I walked out I found a pool of anti-freeze under the engine. First thought was warped head/popped frost plug as the bulk of the fluid was to the rear of the engine. But the raised hood showed most of the spray above the radiator. Thought rad or water pump. A pressure test proved me wrong on all counts, pin hole in heater hose.

Still I'm going to continue a couple more days trying to work out what I think is a carbon issue in the fuel delivery system.

 

[Bulldozer]

Did 200 klm, ummm,125 miles today with no major issues. Mix 50/50 of Hwy and city driving, all be it aggressive city driving when I get the chance. I'm on my 4th can of that intake cleaner, the type used while the engine is running, reved up and hot. I'm also using the Lucas injector cleaner in the fuel tank at a double dose. Switched up to a premium fuel for the time being also, the type with cleaners in it.
Felt a shutter while idling at a road construction site. First chance I got opened hood, took off the intake hose and hit the upper air intake with a long blast of intake cleaner.
Noticed on a couple of the hard accelerations a puff of smoke or a stream of smoke depending on how long an acceleration. Best seen when headlights of other cars light it up for you.