NHTSA Complaint #10725515 — 2012 FORD F-150

I PURCHASED THIS VEHICLE FOR MY SON IN DECEMBER 2012. WE TOOK A TRIP TO ALABAMA ON THE SATURDAY FOLLOWING THE PURCHASE. THE TRUCK HAD PROBLEMS STALLING, MISFIRIING, AND NOT BRAKING IMMEDIATELY. WE HAVE TAKEN THE TRUCK TO THE FORD DEALERSHIP FOR REPAIRS APPROXIMATELY 15 TO 20 TIMES. IT IS IN THE SHOP AGAIN TODAY FOR THE MISFIRING/STALLING. THE SERVICE WRITER TOLD MY SON THAT HIS VEHICLE HAS ONLY BEEN THE SHOP TWICE FOR THE SAME PROBLEM. WE STILL HAVE ALL THE SERVICE PAPERWORK TO DISPEL THAT REMARK, THIS VEHICLE HAS APPROXIMATELY 24,000 MILES ON IT. THE FACTORY WARRANTY EXPIRES IN DECEMBER AND HAS STILL NOT BEEN FIXED. IT DOES NOT JUST STALL IN RAINY OR VERY HUMID CONDITIONS AS STATED BY FORD IN THEIR RESPONSE TO THE NHTSA INVESTIGATION. THEY HAVE REPLACED SPARK PLUGS TWICE, UPDATED SOFTWARE, PUT A HEAT SHIELD IN FRONT OF THE INTER-COOLER. NONE OF THESE THINGS HAVE WORKED. THE SHIELD IN FRONT OF THE INTER-COOLER DEFEATS THE PURPOSE OF THE INTER-COOLER BY NOT ALLOWING IT TO COOL AS INTENDED. IT RAISES THE TEMPERATURE IN THE INTERCOOLER IN AN ATTEMPT TO PRODUCE LESS CONDENSATION. MY SON BELIEVES THE INTER-COOLER HAS A DESIGN FLAW. HE THINKS THAT THE AIR RETURN FROM THE INTER-COOLER TO THE ENGINE BEING ON THE BOTTOM ALLOWS MORE CONDENSATION TO BE SUCKED BACK INTO THE ENGINE. IF IT WERE ON THE TOP, MORE OF THE CONDENSATION WOULD STAY IN THE BOTTOM AND NOT RETURNED BACK TO THE ENGINE. THERE IS AN AFTER MARKET FIX FOR THIS PROBLEM BUT IT IS EXPENSIVE AND I BELIEVE FORD MOTOR COMPANY DOES NOT WANT TO SPEND THE KIND OF MONEY THAT IT WILL TAKE TO FIX THIS PROBLEM CORRECTLY. THIS VEHICLE SHOULD BE ABLE TO OPERATE EFFICIENTLY UNDER ANY CONDITIONS. IF IT DOES NOT, IT IS FLAWED. I WILL PROBABLY HAVE TO PURCHASE THE REPLACEMENT INTER-COOLER OUT OF MY OWN POCKET. I'VE INCLUDED ALL THIS INFORMATION IN THE EVENT THAT IT HELPS OTHERS WITH THE SAME PROBLEM.