Oil Pan and Pump removal and installation

Joe,

I think we went down this road before. According to my Innova Codes, there are two listings for code 538. One is for the issue you are referring to and one is labeled (Trucks Only) "Invalid cylinder balance test due to throttle movement during test". And I never touched the throttle.

Joe,
I may have solved this or at least part of it. Just for fun, and since it's been stuck in the back of my mind, I removed the PCM. I took the cover off and found that two of the capacitors have corroded legs and have broken connections to the circuit board. Rather than trying to change them and since the other components are 30 years old, I was considering a remanufactured one. Are Cardone's reliable or do you prefer other options? Some companies that came up on a search have horrible reviews and terrible BBB ratings.

Thanks,
Tony

That would be a great help Joe. Thanks.

Thanks Joe,
I'll keep you posted.

Hey Joe,

Put in remanufactured ECU/PCM. The good news is that there are no codes, and the transmission is acting normal again. But I still have that rough idle and stuttering on initial acceleration. It seems okay at speed, or at least I can't tell. I even replaced the MAP sensor. I feel like I'm chasing a ghost.
I've read on a Ford Truck forum, others who have the same symptoms. They replaced every sensor, plugs, wires and controllers and still have the problem.

Hey Joe,

The PCM was a "plug and play". The roughness/stumble is in all trans modes, and I feel it throughout the RPM range.

I never removed the IAC when I removed the intake plenum/throttle body, so I took that off to visually check the valve and spring. It was pretty carbon covered so I decided to replace it since I had it off, plus there were a couple of vacuum lines from the throttle body that were in bad shape, so I replaced them also. I rechecked the vacuum, 18" and steady. Well, it now idles worse than before.

Joe, I didn't look into the TB. And no Codes except when I run the KOER test, I still get a 538 on the first test and not on any subsequent test. Could this be an injector issue and not throw a code?

Hey Joe, I took off the IAC valve and inspected inside with a borescope. I can't see anything. I've attached some pics of this and of the vacuum lines I replaced. They are from the vapor canister (starting at a Y fitting) to upper and lower ports on throttle body on the driver side.

No codes. I'd say I drove about 10 miles since I installed the PCM.

Joe,

No change. Since the roughness seems rhythmic and not random, I'm leaning toward a plug, wire, cap or injector. I pulled all the plugs this time and seven look good, only one (cylinder 8) seems fouled. I'm attaching a photo. Let me know your thoughts.
Also, the plugs I pulled, Motorcraft AGSF 32C, are not the correct plugs for this 5.8l motor. Per my owner's manual they are supposed to be ASF 32C. While they are both copper electrode plugs, the threaded ends look to be different lengths. At least what a photo of the correct plug shows. I ordered a platinum tip Motorcraft replacement SP-501 which is supposed to be an upgrade to the ASF 32C.

Joe,

All the other plugs look the same as the one good one in the photo. The carbon fouled looking plug was not wet, although it hasn't been run in a while.

I have never seen any smoke from the exhaust or smelling gas or coolant.

I don't have a coil on the plug ignition system, as demonstrated in your linked video and test procedures. I can't swap any plugs now since I broke 2 getting them all out. I
had such a hard time getting them to turn. I thought they were seized. They have been there for about 15 years (30,000 miles). I had to use a 1/2" impact through the fender well on two, hence the breakage. I should have the new ones tomorrow. I'll also try and scope the cylinder.