Greetings all. I've searched, I've read, I have theories but I'm here to benefit from the collective theory of this forum and the interwebz.
I have a 2002 Excursion 7/3 4x4. I bought it with about 230K mile from an original owner with all records, bone stock and unmolested. I proceeded to put on a lift from CT Performance, zero'd all fluids and filters, new fuel pump/tank cleaned/screens replaced, new starter, batteries are less than 18 month old, etc ad nauseum - suffice to say before purchase I had an out of state Ford dealer do a PPI, then I had my local shop do a PPI, and I fixed everything they both found. My plan/theory/goal was/is to keep this vehicle at least 10 years if not forever. It is my wife's daily driver and I use it when towing our boat or going to our hunting camp.
No tuner, no performance upgrades.
Last week for the first time the vehicle died at speed while my wife was in traffic; a cop pushed her into a gas station. Would crank but not start.
I knew the camshaft position sensor was the most likely suspect - she happened to break down near an Autozone. I was able to install a sensor prior to AAA arriving - truck starts, I am all that is man. I noticed a power steering related hose leaking while I was down there and since the power steering pump and steering box had both been replaced in the past 12 months and I was due for an oil change anyway, it went into my friendly local independent diesel specialist.
Picked it up, drove fine for a few miles in the course of returning a rental and going home.
Next day my wife wanted me to drive it until we knew it was GTG. I dropped off my son at school, headed to the office and it died on me at 50 MPH.
Towed to friendly local independent diesel specialist - they couldn't find any codes, vehicle started right up. Their only theory was that it could be the Autozone sensor. I replaced it with a Motorcraft CPS sensor for peace of mind, drove two miles to Autozone to return their POMS sensor, and when I went back out in the parking lot...
Cracked, wouldn't start.
My son and I walked to a restaurant, had dinner, came back, fired up and drove home.
SO - if that was all TLDR -
Vehicle stalls at speed and won't start until it cools down an hour or so
CPS replaced 2X, now has Motorcraft OEM CPS
No codes being thrown
Played with the pigtail connection a bit, doesn't appear to be the problem
So I know the ICP, IPR, PCM, ECU, wiring harness are the primary suspects
I have searched the forums and I've seen a variety of SIMILAR failure but no smoking gun, and it seems most of those stalls involved vehicles that would start after the stall without having to cool down.
Any brilliant insights as to are appreciated!!! I can't have my wife's DD with three kids stalling randomly and stranding them.
Side note - for those of you unfamiliar with Ron Burgandy - today my Excursion earned the unfortunate nickname Sex Panther - because 60% of the time, it works every time... I'm too much of a noob here to post a youtube link, but google will explain my user name to be a lot less aggressive - if not outright unfortunate - than it might appear at first blush.