NHTSA Complaint #10502362 — 2012 FORD F-150

WHILE TRAVELING AT HIGHWAY SPEED (COLD WINTER MORNING), WITH CRUISE CONTROL ON, STARTED TO CLIMB HILL, ENGINE BEGAN TO THROTTLE UP, THEN THE TRUCK BEGAN TO SHAKE VIOLENTLY, ENGINE LOST POWER. SHUT OFF CRUISE CONTROL AND COASTED ONTO SHOULDER. WAS ABLE TO SLOWLY ENGAGE THROTTLE AND CONTINUE, BUT ANY INCREASE IN THROTTLE ABOVE "GENTLE" WOULD BRING ON THE SHUDDER AND POWER LOSS. ENGINE LIGHT FLASHED AND STAYED LIT FOR NEXT 20 MINUTES. EXPERIENCED SIMILAR SCENARIO LATER THE SAME DAY. TOOK TO DEALER. DEALER INDICATED CHARGED AIR COOLER WORKS "TOO WELL". COOLS AIR SO MUCH THAT CONDENSATION FORMS AND CAUSES THE ISSUE. DEALER INDICATED A TECHNICAL SERVICE BULLETIN HAD BEEN ISSUED ON THE PROBLEM. NEED NEW CAC AND SHIELD. TWO WEEKS (+/-) BEFORE PARTS ARRIVED. DEALER COMPLETED TSB 12-10-19 , ACCORDING TO THE WORK ORDER: REPLACED CAC COOLER ASSEMBLY AND INSTALLED NEW AIR DEFLECTOR SHIELD, REPROGRAMMED PCM. DID NOT FIX THE ISSUE. SAME PROBLEM ON THE WAY HOME FROM THE DEALER. DROVE IT FOR ONE WEEK ASSUMING MOISTURE MAY NEED TIME TO "CLEAR UP". PROBLEM STILL EXISTED FOR 7 DAYS. ANY MILD TO STRONG THROTTLE INPUT WOULD BRING ON SHUDDER. ONE WEEK AFTER "FIXED" WITH NEW CAC, I TRIED TO MERGE ONTO HIGHWAY, AT 60-70 % THROTTLE, VIOLENT SHUDDER OCCURRED AND ENGINE BEGAN TO LOSE POWER. AGAIN, COASTED ON SHOULDER UNTIL TRUCK WOULD RESPOND TO THROTTLE INPUT WITHOUT SHUDDERING AND POWER LOSS. LUCKILY, TRAFFIC WAS "LIGHT" AT THE TIME. COULD HAVE BEEN A SERIOUS INCIDENT. ENGINE LIGHT CAME ON AND HAS NOT GONE OFF FOR 3 DAYS. NOW ANY THROTTLE INPUT BEYOND "GENTLE" BRINGS ON THE SHUDDER. CONTACTED DEALER, GOING BACK IN. TRUCK HAS ECO BOOST V6. *TR