Intermittent problems are always frustrating and hard to find. I hate just throwing parts at a problem because that costs money and introduces new variables into the mix, but you might try a new crankshaft position sensor. They often fail when they get warm, but their air gap is critical too.
New sensors from the dealer will have a thick paper spacer stuck to the end to set that air gap. Many aftermarket sensors have a thin plastic rib molded to the end. It partially wears away during engine operation so to remove and reinstall those, you are to cut off the remaining part of the rib and use a paper spacer from the dealer.
When replacing transmissions at the dealership, I got "smart" and figured I'd save people a few cents by not using that spacer. I just shoved the sensor in as far as it would go, then pulled it back about 1/16th of an inch so it wouldn't hit the flex plate and be broken. Worked fine for the first dozen, but for the thirteenth one, I heard their engine stalled intermittently starting two weeks later and another shop replaced the crank sensor. I suppose it could have been coincidence that the sensor failed, but I suspect it was my fault for not using that spacer. The point is, the problem didn't show up right away.
I'd feel a lot better if there was a fault code stored indicating which sensor was the culprit. The camshaft position sensor could do that too, but they seem to cause a lot fewer problems.
Monday, August 15th, 2011 AT 10:58 PM