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Originally Posted by LunaticSVT
Some known issues that you may want to look into. Each of these can be the root cause of your problem. This will be long and I apologise, but I hope it helps.
The Fuel Pump - Ford had a Recall on this - seee below. A failing fuel PUMP gives bogging at anything more than about half throttle. As it fails, the pump cannot keep up with demand past 50%, the engine goes lean, and will cause the issues you are describing.
According to Ford:
1. New pumps exist now but they are backordered.
2. Dealers can install a temporary pump for cars with real bad problems. Later, new pumps can be installed.
3. All this is covered under warranty. No mileage limit or time limit. Even if you're not the original owner.
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Dielectric - You will need to have the dielectric grease on the plugs. If not you will damage the plugs and possibly boots. If the dealer has put the wrong grease on it they should be responsible to replace with the correct grease. Using the wrong grease will also cause issues and possible damage.
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DPFE - If you are getting a CEL code "EGR flow insufficient" then replacing the DPFE will usually fix this problem. You will experience bucking, hesitation and stuttering under heavy loads or heavy acceleration.
Hope that this is of some help.
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I have a 2002 V6 2.5L MTX Cougar that is experiencing the same hesitation under accel. This mainly occurs in higher RPMs through only 3RD though I have felt in all gears. My car has been in the shop three times now:
1ST - Fuel Sending Unit replaced
2ND - CEL (EGR Excessive Flow) EGR Replaced
3RD - CEL (EGR Excessive Flow) Pressure Sensor Replaced
Should I take it back and tell them to replace my DPFE (or should I do it myself)? Any help here would be greatly appreciated
