2006 GT Intermittent engine stutter/stumble & then surge - Ford Mustang Forum
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post #1 of 14 (permalink) Old 2 Weeks Ago Thread Starter
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2006 GT Intermittent engine stutter/stumble & then surge

Hello Forum members.

It's been a while (like probably a couple of years) since I first posted about this judder/surge problem & I still haven't been able to work out what is going on & fix it, despite trying quite a few things.

I hoping that someone might be able to help with an intermittent engine stutter/stumble & surge issue that I'm having with my 2006 GT (stick shift, 160,000 miles).

This randomly happens when cruising (e.g., on the highway at 60 mph, or in residential areas when under gentle throttle).

Feels like the engine dies for a split second & then it catches itself & surges briefly, which, being a stick shift, makes a massive judder & feels like the car is jumping forward (when driving slowly) & like it is dying (when on the highway).

Things I have done so far (in order)...

1) Checked for codes none

2) Throttle body & MAF cleaned

3) Throttle body replaced (as a complete unit)

4) New fuel filter

5) New fuel pump

6) New spark plugs

7) Checked alternator (OK)

9) Swapped CAI for standard intake & reinstalled factory tune (still judders) - different MAF in stock intake

10) New camshaft sensors

11) New battery

12) New Crank position sensor

Nothing has made any difference & I am at a loss what to try next. Has anyone else experienced this or can suggest what the problem might be?

Thanks in advance for any help!


The list of things done so far (still in order, following on from above)...

13) Replaced fuel pump relay


2006 Mustang GT Convertible
2004 GT hood scoop, LeMans stripes, K & N, sequentials, strut brace, underhood & interior billet, tinted lights, custom paint, & lots of miles.
It's my daily - wind, rain, snow, sun - seen them all!

Last edited by Granada302; 1 Day Ago at 04:57 PM.
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post #2 of 14 (permalink) Old 2 Weeks Ago
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When you replaced your throttle body, did you replace the motor and the throttle position sensor as well?

You may also want to check your coil packs.

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post #3 of 14 (permalink) Old 2 Weeks Ago
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I was going to suggest the fuel pump but you've already replaced it. However it still sounds like you have a fuel delivery problem so I suggest you check the fuel pump relay and its electrical contacts for contamination. You could even swap it with another relay to see if the problem goes away.
Also pull the fuel pump and check if the filter sock is clean. It's possible it could be clogged up with sediment from the bottom of the tank. If that's the case, you'll need to have the tank cleaned.
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post #4 of 14 (permalink) Old 2 Weeks Ago Thread Starter
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Thanks for the suggestions.

Replaced the TB as a complete unit...included the stepper motor & TPS.

Coil packs are on my list of things to replace but was hoping it might not be so trial & error.

Thanks!

2006 Mustang GT Convertible
2004 GT hood scoop, LeMans stripes, K & N, sequentials, strut brace, underhood & interior billet, tinted lights, custom paint, & lots of miles.
It's my daily - wind, rain, snow, sun - seen them all!
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Thanks for the suggestions.

Was expecting the fuel tank to have at least some sediment in it (especially with 150K) but it was spotless.

Will check the fuel pump relay & clean the contacts...

Thank you!

2006 Mustang GT Convertible
2004 GT hood scoop, LeMans stripes, K & N, sequentials, strut brace, underhood & interior billet, tinted lights, custom paint, & lots of miles.
It's my daily - wind, rain, snow, sun - seen them all!
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post #6 of 14 (permalink) Old 2 Weeks Ago
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A stutter or stumble is unlikely to be caused by an ignition or even an injector misfire unless multiple cylinders are affected simultaneously. Rough running, a lack of power, and increased fuel consumption are the more common symptoms.
I'm confident that your problem is fuel pump related and is either electrical or mechanical (bad fuel pump right out of the box).
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post #7 of 14 (permalink) Old 2 Weeks Ago
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I see you cleaned the MAF, but not replaced it. It is pricey for such a small part and there are other things that could cause the issue as well, but I believe a bad MAF could cause similar issues.
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post #8 of 14 (permalink) Old 2 Weeks Ago Thread Starter
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Thanks for the suggestion.

When I swapped the CAI & custom tune out for the stock tune & intake I have a replacement MAF in the stock intake so that I don't have to swap the MAF between the intakes - I can just swap the entire intake over.

Since the problem is still happening with both intakes, unless both MAFs have the same problem, I'm hopeful that the MAF isn't the issue (although it would be a easy solution).

I will take a look at the MAF wiring harness just to make sure that isn't causing an issue.

Thank you!

2006 Mustang GT Convertible
2004 GT hood scoop, LeMans stripes, K & N, sequentials, strut brace, underhood & interior billet, tinted lights, custom paint, & lots of miles.
It's my daily - wind, rain, snow, sun - seen them all!
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Quote:
Originally Posted by Granada302 View Post
Hello Forum members.
It's been a while (like probably a couple of years) since I first posted about this judder/surge problem & I still haven't been able to work out what is going on & fix it, despite trying quite a few things.
So this has been going on for years inspite of all the replacement parts you've thrown at this?
Personally, I can't help but to think this is something electrical.
My first thought is the plastic connections to each injector.
You have an 06 that's been daily drivin for a long time. Wire and plastic male/female connections get brittle and corrode after a while.
Any more info for us interweb mechanics would be greatly appreciated.
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20% tint, smoked markers and tail lights w/sequentials. Clear front signal covers, series 3 chin spoiler.
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Quote:
Originally Posted by Granada302 View Post
Thanks for the suggestions.

Replaced the TB as a complete unit...included the stepper motor & TPS.

Coil packs are on my list of things to replace but was hoping it might not be so trial & error.

Thanks!

Did you check the previous TPS voltage and set the same voltage on the new TPS?
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post #11 of 14 (permalink) Old 1 Day Ago Thread Starter
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Thanks for all the suggestions so far...

Unfortunately, nothing has changed

Checked the fuel pump relay & all good. Just for good measure replaced it, but no difference.

New OEM fuel pump made no difference at all. Checked the electrical connectors when I swapped the pump out. Fairly confident that the new pump is OK (symptoms are identical), but could well be an electrical connection somewhere else in the circuit. Haven't checked the fuel pump driver module & connections yet, so that's probably my next step.

TPS voltage OK, too.

Electrical connections are certainly becoming brittle...or at least some of them are - recently swapped out my headlight bulbs & the connector clips just fell apart.

To try & provide more information this intermittent hesitation seems to typically occurs when under part throttle cruising at 60/65 on the highway or under part throttle on other roads (say when gently driving at 25 in subdivisions). When accelerating this doesn't happen. Timing can be anything...might be 40 minutes after starting to drive or maybe only 10 minutes. Sometimes it doesn't do this for a couple of weeks, or it can be multiple times in a day.

Since I'm still at the trial & error stage with no check engine light, no codes, & an intermittent issue, thought that maybe the throttle could be the problem (with 160K now on the car, maybe the switch is worn), but since this also happens using cruise control, seems that would rule the pedal out).

Kinda given up driving my Mustang over the last year or so as a daily (due to this) & only taking it out after checking/replacing something, but with the summer rapidly approaching it would be nice to be able to get this sorted

Thanks in advance for any further help/suggestions!

2006 Mustang GT Convertible
2004 GT hood scoop, LeMans stripes, K & N, sequentials, strut brace, underhood & interior billet, tinted lights, custom paint, & lots of miles.
It's my daily - wind, rain, snow, sun - seen them all!
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post #12 of 14 (permalink) Old 18 Hours Ago
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What kind of plugs did you use for replacements? Also, if you're able to get your hands on a known good coil pack, you can try swapping it in one at a time to see if you have a weak coil.

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post #13 of 14 (permalink) Old 12 Hours Ago
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Quote:
Originally Posted by Granada302 View Post
Thanks for all the suggestions so far...

Unfortunately, nothing has changed <img src="https://www.allfordmustangs.com/forums/images/smilies/frown.gif" border="0" alt="" title="Frown" class="inlineimg" />
That's terribly frustrating. You've checked all the obvious things so now we're going to be looking for something more obscure.
You still haven't ruled out the fuel pump driver module or the wiring to it so that would be my next step.
I suggest you buy an ELM 327 Bluetooth OBD 2 module that plugs into your underdash OBD 2 port. You can download a scanning software onto your smartphone (I use Car Scanner and it works great) that connects to the Bluetooth module, and monitor live data as you drive. Hopefully it'll pick up a fault when the engine stumbles and help you troubleshoot it.
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post #14 of 14 (permalink) Old 7 Hours Ago
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Could also be the fuel pressure sensor. I'm with Bullitt, get an ELM 327 and use one of the apps (I use Torque Pro) to monitor a few vitals such as fuel pressure.

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