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Old 06-06-2013, 01:44 PM   #11
Focused_On_Graton
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Thanks everyone!

Idle is perfectly fine... except when the problem occurs of course. Then it's sputtering and choking. - - - I've had the car from 40k on to 106k... yes fuel filter has been replaced.

Interesting: seems to happen most often when A/C is engaged. Also, I've noticed a correlation when I move from high speeds to low speeds.

READY FOR THIS? 2-3 years ago, my son kicked the "emergency shutoff" switch (lower passenger floorboard) This created similar circumstances. Finally found it, plugged it back in, and all was well. THEN the passenger door seal developed a bad lead during rains (because of Thule rack) - - - and tons of water end up on my passenger floorboard after a storm. The lead moves water right on top of that "emergency shutoff" switch. AAARGH! how can this still play a role? it's summer and no rain for quite a while... so damn weird.
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Old 06-06-2013, 06:15 PM   #12
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Constant water on a switch would cause corrosion. The switch controls the fuel pump.
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Old 06-06-2013, 06:36 PM   #13
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Right. But, wouldn't corrosion create some kind of consistent issue?
How can I check for that? THANKS.
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Old 06-06-2013, 11:13 PM   #14
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If there is corrosion on the switch, then any slight movement or bump can move the wires causing it to get a bad connection. Once the wire moves again, it could be getting a better connection, causing your issues to temporarily go away. Pull the panels off, and look at the switch connections to see how they look.
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Old 06-06-2013, 11:16 PM   #15
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It's allowed to be intermittent until it fails completely. Pull the connector from the switch. Connector should have two connections. Make a safe jumper wire to go from one connection to the other (replacing the switch with the jumper). If the problem goes away then you have a bad switch. Either way you only by-pass the switch for diagnostic purposes. The fuel cutoff switch is a safety device to prevent you from dying by fire during an accident!!!!
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Old 06-07-2013, 10:32 AM   #16
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"Most often when A/C is engaged, or moving from high to low speeds" makes me wonder if a sticky IAC (Idle Air Control) valve could be involved.

This controls idle speed, adjusts for the load of the A/C, resets idle speed after decel. SO, if it isn't always responding right idle could be too low & quite rough.

Another possibility for you.

Luck!

P.S. - they can be removed/checked/cleaned to see if things improve. Don't have to try a new one just to check it out.
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Old 06-08-2013, 01:00 AM   #17
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Thank you to everyone.
I will try the suggestions:
1) pull and check for corrosion
2) REmove , clean, the Idle Air Control
Will probably take me weeks to get these things done... will report back when complete.
Thanks again! - David
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Old 07-03-2013, 01:02 PM   #18
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Good People and Fine Exerts! I threw in the towel. Car is now at the Ford dealer in Santa Rosa, CA. Claim they have a certified Ford Master mechanic here. The guy behind the counter (basically) scoffed when I attempted to show him all of your good suggestions... ego is a funny thing. In this case, an annoying thing. I'll report their findings and solution, before I toss a few eggs at the dealership window... jk :-)
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Old 09-27-2013, 03:45 PM   #19
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Hello. I told y'all I would report on this insane issue: After 3 trips to the local Ford dealer (with reportedly "master mechanics" on board) they found NOTHING. Another shop did a different diagnostic, and fuel pump and fuel pump controller were indicated. I was begrudgingly willing to shell out the $1,400 to have them replaced. Then the dealership Shop Foreman called and said he had found an obscure warrantly clause for the PZEV engine, and would replace them free of charge! Hallelujah! Brought it in, they replaced the fuel pump and fuel pump controller module. Two days later I went to pick up the vehicle. And within 3 minutes of driving, I lost power and the car stalled, same exact symptoms. Is this car possessed? EEEEEEEk!
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Old 09-27-2013, 04:31 PM   #20
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Do the Focus AC compressors have the teflon seals that lead to "black death" ?
Isn't that where the PCM is mounted (passenger footwell)?
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