Bronco 2.7L Engine Stall

[zzettle]

My Bronco 2.7L 4dr with 10k miles started stalling while driving about 4 weeks ago. Electronic displays were on and the only error message was to pull over and restart the engine. To restart the engine it took 5-6 attempts. After driving 5 miles and stalling 6 times I had it towed to the nearest dealership where it has been sitting for 4 weeks now with no resolution. I have been in communication with the dealership every day now and they are running out of options to troubleshoot. My instant thought was the fuel pump, but pin testing has determined to be functioning normal. Ford is now sending out an engineer this week to assist with troubleshooting, but I am curious if anybody has experience with this or have any insight?

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[PWillette]

So not throwing any codes at all? Possible bad gas or plugged fuel filter/line maybe.

 

[da_jokker]

Sounds like you got one of the bad Fuel pumps. Plenty of threads about it.

 

[zzettle]

Fuel pump was determined to be functional based off of the pin testing. Dealer just notified me that they took off the catalytic converter and found the honeycomb structure was completely melted. Ford engineers are saying this is the first bronco they have seen with this issue and are trying to investigate the root cause.

Ford better sharpen their pencils for an extended warranty.

 

[Rspayde]

Fuel pump was determined to be functional based off of the pin testing. Dealer just notified me that they took off the catalytic converter and found the honeycomb structure was completely melted. Ford engineers are saying this is the first bronco they have seen with this issue and are trying to investigate the root cause.

Ford better sharpen their pencils for an extended warranty.

If you are purchasing an extended warranty go through Grainger. But I am imagining you are speaking of a more on the house type scenario.

 

[da_jokker]

Man it must have dumped alot of unburnt fuel down there to do that. Will be interesting to see what they find.

 

[zzettle]

Vehicle is still not fixed.

 

[zzettle]

 

[jayohdub]

This exact thing just happened to mine yesterday--they have it but I haven't heard back yet. Did you ever figure out the issue?

 

[Ford Motor Company]

This exact thing just happened to mine yesterday--they have it but I haven't heard back yet. Did you ever figure out the issue?

Hello! Could you please send us a PM with your VIN and the name and location of your Ford dealer? I'd be happy to see how I can assist you with this stalling concern.

 

[zzettle]

This exact thing just happened to mine yesterday--they have it but I haven't heard back yet. Did you ever figure out the issue?

They ended up replacing the fuse box.. when removing the fuse box they found a damaged wire for the emissions system. This caused unburnt fuel to be dumped into the catalytic converters. After they installed the new wire, bank 1 & bank 2 catalytic converters needed to be replaced.

 

[jayohdub]

They ended up replacing the fuse box.. when removing the fuse box they found a damaged wire for the emissions system. This caused unburnt fuel to be dumped into the catalytic converters. After they installed the new wire, bank 1 & bank 2 catalytic converters needed to be replaced.

Was it a manufacturing defect with the fuse box/wire?

 

[zzettle]

Was it a manufacturing defect with the fuse box/wire?

Yes. No aftermarket upgrades were done in this area. It was deemed it rolled off the manufacturing floor like this. Covered fully by manufacturing warranty.

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