A/C Clutch stuttering on/off.

[AZExploder]

2010 Mercury Mountaineer AWD 4.6l 3V - 260,000

Issue has been going on for about 3 summers now.

AC is fine all fall, winter (defrost), and spring. Temps climb over 105 - 120 deg the symptoms come back.

Recent Replacements chasing issue with the advice of ASE tech and all Ford/Motorcraft parts to no avail:

1. New AC - all of it
2. New COPS/Plugs
3. New Injectors
4. New Intake
5. New Wiring harness (another thread has that disaster)

Symptoms:

1. Engine runs fine with AC turned off - all the time.
2. Engine runs fine with AC turned on until warmed up, then clutch stutters and engine bogs and hesitates, coughs and bucks.
   1. Stutter lasts 10-20 seconds, then clutch disengages
   2. Stays disengaged for 10-20 seconds
   3. Engages for 10-20, then stutter returns and cycle repeats.
3. Turn off AC, engine runs fine again all day as I slowly melt away.

stutter = on/off 2-3 times a second.

Today fiddled with the low side AC with a cr@p gauge. After warming up and the clutch disengaged, I released some freon for a second. Once the clutch engaged and then disengaged after stutter, released more. Repeated several times. Low side pressure slowly minimized in the green and maximized just into the red. It seemed to reduce the stuttering and bucking. It has "cooled " down to 100 so not a great time to test. Will tomorrow.

Any suggestions?

 

[Gmctyphoon]

I was interested when this was on the engine harness thread. So I’ll still try to help here.

You gave a lot of great info, and a weird problem. When you say all of the ac, do you mean ALL? Compressor, condenser, lines, expansion valve, evaporator, orifice tube? Who filled the ac and how?

Have you cleaned the throttle body or MAF sensor lately or ever. 260k miles is a lot, and all sorts of stuff can be messing those two up.
For this issue I’d me more interested in the throttle body.

 

[AZExploder]

Last night I pulled the top side of the wire harness - COPS, injectors, sensors - and dabbed a bunch of dielectric goo on each plug and re assembled. I also charged up the battery. I took for a spin up and down the new freeway at 65 for around 30 minutes. After worm up - about 2 miles/4 min, she ran fine without AC, ran like poo with AC on. I only ran the AC for 2 min or so to confirm the stutter was ongoing at various speeds.

I got off the freeway and within 30 seconds i got the wrench and limp mode engaged. Trans would not shift up from 3rd.

Codes at the time: P0054/ P0060/ P0073/ P1000

 

[AZExploder]

Tonight I pulled the airbox and found a bundle of wires under the box that where visibly marked from the box sitting on them. I pulled the wires apart and they were stuck - as in the jackets were welded together. None seemed to be broken or warn though. After separating them, i wrapped them in tape and then taped them into the proper channel they had moved out of over the years.

 

[AZExploder]

I was interested when this was on the engine harness thread. So I’ll still try to help here.

You gave a lot of great info, and a weird problem. When you say all of the ac, do you mean ALL? Compressor, condenser, lines, expansion valve, evaporator, orifice tube? Who filled the ac and how?

*** All of it was done my the guy who has been working on all my cars for 8 years, including multiple AC jobs in F250, Expeditions, evac and charges in my hondas and mercurys. I believe it was the entire kit from FoMoCo - hoses, and hard parts. Seems the AC compressor is a difficult bugger to get out.

Have you cleaned the throttle body or MAF sensor lately or ever. 260k miles is a lot, and all sorts of stuff can be messing those two up.
For this issue I’d me more interested in the throttle body.

*** Cleaned the MAF regularly when I oil the filter. Cleaned the TB when I replaced the Intake Manifold.

 

[AZExploder]

Also tonight - I pulled the trans plug and verified the pins were intact and they checked out fine. Looked for burnt of frayed wires, vacuum tubes, anything out of the ordinary.

Test drive for 45 min ran fine. AC continues to blow - in a bad way.

FORScan Codes below:

===APIM DTC U3003:16-28===
Code: U3003 - Battery Voltage

Additional Fault Symptom:
- Circuit Voltage Below Threshold

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: Accessory Protocol Interface Module
===END APIM===

===TCM DTC U0073-FF===
Code: U0073 - CAN communication bus fault

Module: Transmission Control Module
===END TCM===

===PCM DTC P0053-FF===
Code: P0053 - HO2S11 heater resistance out of limits.

Module: Powertrain Control Module
===END PCM===

===PCM DTC P0054-FF===
Code: P0054 - HO2S12 heater resistance out of limits.

Module: Powertrain Control Module
===END PCM===

===PCM DTC P0059-FF===
Code: P0059 - HO2S Heater Resistance (Bank 2, Sensor 1)

Module: Powertrain Control Module
===END PCM===

===PCM DTC P0060-FF===
Code: P0060 - HO2S Heater Resistance (Bank 2, Sensor 2)

Module: Powertrain Control Module
===END PCM===

===PCM DTC P1000-FF===
Code: P1000 - On-Board Diagnostic (OBD) Systems Readiness Test Not Complete

Module: Powertrain Control Module

===END PCM===

===OBDII DTC P0053-P===
Code: P0053 - HO2S11 heater resistance out of limits.

Status:
- Pending - malfunction is expected to be confirmed

Module: On Board Diagnostic II
===END OBDII===

===OBDII DTC P0054-P===
Code: P0054 - HO2S12 heater resistance out of limits.

Status:
- Pending - malfunction is expected to be confirmed

Module: On Board Diagnostic II
===END OBDII===

===OCS DTC ===
Successful DTC reading, no error codes found

Module: Occupant Classification System Module
===END OCS===

===4X4M DTC B1318-2F===
Code: B1318 - The battery voltage level is too low.

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: 4X4 Control Module

Diagnostic Trouble Code details

Battery Voltage Too Low

--- Possible Causes --------

- Battery Voltage below 9.6volts

-Suspect Battery state of charge Charging system


===END 4X4M===

===4X4M DTC U1900-2F===
Code: U1900 - CAN Communication Bus Fault - Receive Error

Status:
- Previously Set DTC - Not Present at Time of Request
- Malfunction Indicator Lamp is Off for this DTC

Module: 4X4 Control Module

Diagnostic Trouble Code details

CAN Communication Bus Fault - Receive Error

Note:

DTCs that start with 'U' are faults which occur during module-to-module communication.

Modules should never be replaced based only on a 'U' code. These codes do not always indicate a problem, and can be caused by normal diagnostic functions, carried out on the vehicle.


===END 4X4M===

===ABS DTC ===
Successful DTC reading, no error codes found

Module: Antilock braking system
===END ABS===

===RCM DTC ===
Successful DTC reading, no error codes found

Module: Restraint Control Module
===END RCM===

===IC DTC ===
Successful DTC reading, no error codes found

Module: Instrument Cluster
===END IC===



FORScan DTC list
Mon 8/3/2020 8:19 PM

 

[AZExploder]

Has new alternator - battery is just over 3 years old.

 

[AZExploder]

so - tonight - drove into the hills above Phx and just a tad of a trail drive - cool down and see some stars

I reset the computer and installed a new battery. 130 miles and 4 hours was not enough to clear the P1000, but the rest of the FORScan are below:

P0011 , P0021 ,P0054 ,P0060, P0341, P0346, P2195, P2197, P0011, P0021, P0054,

===PCM DTC P0011-FF===
Code: P0011 - Intake Camshaft Position Timing - Over-Advanced (Bank 1)
Module: Powertrain Control Module
Diagnostic Trouble Code details
Intake Camshaft Position Timing - Over-Advanced (Bank 1)
This DTC may be caused by :
The solenoid may be mechanically stuck
Engine mechanical fault.
===END PCM===

===PCM DTC P0021-FF===
Code: P0021 - Ignition Signal(IGNS).
--Possible Causes--
- Damaged resistor/condenser.
- Damaged power transistor.
- Open in coil VPWR circuit.
- Open in PCM output signal circuit.
- Short to GND in PCM output signal circuit.
- Open in coil GND circuit.
- Open in PCM input signal circuit.
- Damaged coil.
- Damaged PCM.

Module: Powertrain Control Module
Diagnostic Trouble Code details
Ignition Signal(IGNS).
--Possible Causes--
- Damaged resistor/condenser.
- Damaged power transistor.
- Open in coil VPWR circuit.
- Open in PCM output signal circuit.
- Short to GND in PCM output signal circuit.
- Open in coil GND circuit.
- Open in PCM input signal circuit.
- Damaged coil.
- Damaged PCM.
===END PCM===

===PCM DTC P0054-FF===
Code: P0054 - HO2S12 heater resistance out of limits.
Module: Powertrain Control Module
===END PCM===

===PCM DTC P0060-FF===
Code: P0060 - HO2S Heater Resistance (Bank 2, Sensor 2)
Module: Powertrain Control Module
===END PCM===

===PCM DTC P0341-FF===
Code: P0341 - Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or single sensor)
Module: Powertrain Control Module
Diagnostic Trouble Code details
Camshaft Position Sensor A Circuit Range/Performance (Bank 1 or single sensor)
Follow the routines in the service manual to resolve the DTC listed.
===END PCM===

===PCM DTC P0346-FF===
Code: P0346 - CID A Circuit Range/Performance (Bank 2)
Module: Powertrain Control Module
===END PCM===

===PCM DTC P2195-FF===
Code: P2195 - HO2S11 not switching correctly. Sensor indicates lean.
Module: Powertrain Control Module
Diagnostic Trouble Code details
HO2S11 not switching correctly. Sensor indicates lean.
Air leaks at the exhaust manifold
This DTC may be caused by :
Low fuel pressure.
Manifold vacuum leak.
HO2SHTR11 Heater Circuit Malfunction
===END PCM===

===PCM DTC P2197-FF===
Code: P2197 - Lack of HO2S21 Switch Sensor indicates Lean
Module: Powertrain Control Module
Diagnostic Trouble Code details
Lack of HO2S21 Switch Sensor indicates Lean
Suspect HO2S21.
This DTC may be caused by :
Ignition misfire.
Low fuel pressure.
Manifold vacuum leak.
Disconnected or Damaged vacuum hose.
Restricted or Damaged fuel injector.
Suspect PCM.
===END PCM===

===OBDII DTC P0011-P===
Code: P0011 - Intake Camshaft Position Timing - Over-Advanced (Bank 1)
Status:
- Pending - malfunction is expected to be confirmed
Module: On Board Diagnostic II
Diagnostic Trouble Code details
Intake Camshaft Position Timing - Over-Advanced (Bank 1)
This DTC may be caused by :
The solenoid may be mechanically stuck
Engine mechanical fault.
===END OBDII===

===OBDII DTC P0021-P===
Code: P0021 - Ignition Signal(IGNS).
--Possible Causes--
- Damaged resistor/condenser.
- Damaged power transistor.
- Open in coil VPWR circuit.
- Open in PCM output signal circuit.
- Short to GND in PCM output signal circuit.
- Open in coil GND circuit.
- Open in PCM input signal circuit.
- Damaged coil.
- Damaged PCM.
Status:
- Pending - malfunction is expected to be confirmed
Module: On Board Diagnostic II
Diagnostic Trouble Code details
Ignition Signal(IGNS).
--Possible Causes--
- Damaged resistor/condenser.
- Damaged power transistor.
- Open in coil VPWR circuit.
- Open in PCM output signal circuit.
- Short to GND in PCM output signal circuit.
- Open in coil GND circuit.
- Open in PCM input signal circuit.
- Damaged coil.
- Damaged PCM.
===END OBDII===

===OBDII DTC P0054-C===
Code: P0054 - HO2S12 heater resistance out of limits.
Status:
- Confirmed - malfunction is confirmed
Module: On Board Diagnostic II
===END OBDII===

===PCM DTC P1000-FF===
Code: P1000 - On-Board Diagnostic (OBD) Systems Readiness Test Not Complete
Module: Powertrain Control Module
Diagnostic Trouble Code details
Check of all systems is not complete since last memory clear.
--Possible Causes--
- The vehicle is new from the factory and has not yet been through a complete OBD Drive Cycle.
- The battery or PCM has been disconnected.
- An OBD monitor failure had occurred prior to completion of an OBD Drive Cycle.
- The PCM DTCs have been cleared as part of a service process.
Note: The only way P1000 can be cleared (removed) from memory is when all of the OBD monitors have been successfully completed during normal vehicle operation.
P1000 cannot be cleared from the PCM when: 1. The thermostat is stuck open and a DTC is not generated. 2. There is an open VSS circuit and a DTC is not generated. 3. If the vehicle has a Power Take Off (PTO), the circuit is shorted to VPWR or B+, or the PTO is ON during Self-test.
The purpose of the Diagnostic Trouble Code DTC P1000 is to indicate that not all of the On Board Diagnostics OBD monitors have yet been successfully completed. You may also refer to the OBD Drive Cycle defined under the Powertrain Control/Emission Diagnosis Manual-Diagnostic Methods or the Owner's Manual.
Remember: It is not necessary to remove P1000 from the Powertrain Control Module PCM by driving the vehicle.
===END PCM===

===OCS DTC ===
Successful DTC reading, no error codes found
Module: Occupant Classification System Module
===END OCS===

===APIM DTC ===
Successful DTC reading, no error codes found
Module: Accessory Protocol Interface Module
===END APIM===

===TCM DTC ===
Successful DTC reading, no error codes found
Module: Transmission Control Module
===END TCM===

===4X4M DTC ===
Successful DTC reading, no error codes found
Module: 4X4 Control Module
===END 4X4M===

===ABS DTC ===
Successful DTC reading, no error codes found
Module: Antilock braking system
===END ABS===

===RCM DTC ===
Successful DTC reading, no error codes found
Module: Restraint Control Module
===END RCM===

===IC DTC ===
Successful DTC reading, no error codes found
Module: Instrument Cluster
===END IC===

 

[AZExploder]

My Ebay PCM fell though after waiting 2 weeks - so I got another one ordered from Flagship One online.
now i wait.. again.

 

[AZExploder]

Had to cancel the Flagship One computer - 3 weeks they had my $500... called 8 times and emailed same.. never any contact. Had Paypal get my money back.

Finally got another PCM - had Ford program and update, and drove fine for a day and 50 miles..

.... aaaand, just limped home over city streets for 60 miles, not able to shift out of 2nd..

and new codes, same as the last..

Car Scanner ELM OBD2
DTC report
Selected brand: Mercury
VIN: 4M2EN4J84AUJ01534

============1==============
U0101
Raw code: C101
ECU: Engine control unit
Status: Pending
OBDII: Data bus, transmission control module (TCM) - no communication
============2==============
U0100
Raw code: C100
ECU: Transmission control unit
Status: Pending
OBDII: Data bus, engine control module (ECM) A - no communication
============3==============
U0073
Raw code: C073
ECU: Transmission control unit
Status: Pending
OBDII: Control module - data bus Off
============4==============
U1900
Raw code: D900
ECU: ABS/ESP
Status: Validated and stored in non volatile memory, Validated fault present at time of request, Validated fault has been present during this drive cycle

 

[AZExploder]

I saw this post so I invested an hour or so cleaning and jumping grounds using some leftover amp power wire..

Electrolysis, stray voltage, bad grounds, the "Big 3" and more...

So, the Sport Trac is 5 years old, but we've had it for a year. After a failed left front hub, and the trans going south, I've decided to start from scratch with the maintenance/routine. So, fluids were first. The oil, trans, transfer case were recent, now the coolant. While testing, I...

www.explorerforum.com

aaannd.. no.. Quest continues..

 

[AZExploder]

so.. the "Shop of Last Resort" spent a few hours and $450 of my cash to tell me it was the TCM that needed to be replaced... for another $2400.

That triggered a memory of another shop 6 years ago that told me the same thing.

At that time, my shade-tree suggested the wire harness sleeve in the back of the trans. I completed that with the help of FordTechMakuloco video and truck ran for 5.5 years just fine.

THIS time, I looked back at the videos FordTechMakuloco posted, and he had an addendum to the first video:

That second video showed the sleeve produdes 16mm. I measured mine - it was 21mm.

So, dropped pan, pulled the sleeve, and the first o-ring was fully exposed to the elements. I still had the OEM sleeve from 6 years ago.. duno why. So I pulled the good o-ring off and replaced the exposed one. Then cleaned the sleeve, lubed the rings with lots of t-fluid, and took 5 min trying to shove it in to the 16mm indicated in the video. I would get close, only to have the retainer clip engage and push the sleeve out.. The key is to HOLD the sleeve fully engaged in as you lift the retainer. That is where my fail was originally.

So far - $60 in oil, 2 days, 5 trips, about 50 miles.. and no hiccups. A/C still does not work, but that is for another day..