PhotoAl

Im thinking something didn't go back together the way it was before, check all of the connections on the turbo and waste gate to make sure something isn't swapped, loose or disconnected. Im not familiar with the Ford turbos but most turbos Ive had have a waste gate and if the control is messed up then it could overboost which would cause the swelling - not a good thing as you can tell.

Thanks, that is a very interesting file.

I think this thread has been overloaded ..... :-)

With age rubber bushings deteriorate and you can get rattles and looseness. I'd be more concerned about the clunk. Many years ago we had a GMC Safari van that had a clunk in the right front - from new. Dealer said they tore it apart and found nothing, had an independent mechanic look at it, he and I even test drove it and we both could hear and feel it. Finally a few years later my wife was turning around in her parents driveway. Clunk and the right front wheel fell over!!!! Good it happened at 1 MPH - ball joint. Had it replaced and several years later same think happened, she was going 10 or 15 at the time and just pulled over. The van went to Pull-a-Part with 200,000 miles on it when I was getting ready to buy the TC a year and a half ago. She misses it, I don't. I don't think the suspension on the 1st generation is that bad, and if you need to replace parts its not too difficult or expensive.

Normally if you have too much pressure it will back off the turbo or bleed some of the pressure off. Has something changed with the boost control? Is there blockage in the intercooler?

LOL, cars are indeed getting better and safer all the time. Used to be you could buy some stupidly unsafe cars but today every car out there is reasonable safe and quite reliable. When airbags were first introduced I saw a study that drivers of cars with airbags felt safer and therefore took more chances and actually had worse crashes. I believe that trend has continued with many drivers feeling safe and therefore willing to take additional risks. Just because you do something dangerous every day and are not harmed by it does not make it any safer.

Agree with others comment about the transmission. I have the roof rails which are nice for mounting the crossbars on. I even bought a set of crossbars from a forum member. However I've never used them. Mine has the trailer hitch from the factory which is nice but Ive not done much hauling with it. My thoughts are a trailer is preferable to the roof rack as the roof rack adds noise and hurts gas mileage. A small lightly loaded tailer will hurt gas mileage and be quieter than stuff on the roof. From what I know the rails are hard to mount. So far everything Ive needed to cary has fit inside. I do have a project which will involve 12 foot lumber but will probably put it on my trailer. Ive had my 2016 for a little over a year and only have 13,000 miles on it. It is supposed to be for haling stuff and taking longer drives. For a while it was my daily driver.

WeatherTech make one. I have the 6 seat configuration in a Titanium. Its $69.95. I did not get it but do have the ones for the front and middle. I have been very happy with them. Also have the big mat that goes over all the seats when they are folded. Not cheap but good stuff and well made.

Ive not had any trouble dragging the bottom but don't drive over anything that difficult. My other car is a Volt which is very low so this seems better in that respect. The front and rear overhang is not much and Ive not had a problem with them.. May have scrapped the front a little bit one time. In my neighborhood we have lots of steep driveways and plenty of opportunity to scrape but the TC doesn't seem to be bad. Being low does make it easy to get in and out of. My daughter has a Honda Oddessy which is higher off the ground but interior room is less due to the low top (relative to the floor). The TC rides a bit stiffer than the Honda but goes around turns much better - can almost be fun in the corners as it doesn't roll too much and the tires are descent. I had to be vey careful with the Volt with OEM tires as they gave up very early. I almost ran off the road one time not paying attention - lit up all the stability control lights! I was on a road that I frequently rode my sport bike on and thought I was going slow enough. LOL learned that lesson! Ive cemented on this before, the TC is my retirement haul people and stuff van. I haul a scooter around, sometimes taking ou the rear seats - 4 bolts not too bad but they are not lightweight. I haul stuff ranging from dishwashers to double ovens and IKEA cabinets. Daaughter's Honda is a little longer and can could the longer cabinet boxes. I haul people, recently father-in-law was dying of cancer and I hauled him, wheelchair, my wife, mother-in-law and caregiver to the doctors office. Easier to get him and mother-in-law in and out as the seat height is neither up or down. Just back in and sit down. The inlaws were 90 at the time and mother-in-law has very bad arthritis. On the other end of the spectrum there are the twin 5 year old grandkids. They don't complain but fight over which side they sit on - right side has a better view of the navigation map. Last summer I took the rear seats out and folded one of the middle two flat and then hauled my wife and another daughter 600 miles to Florida. Along with a mountain of stuff! Put my bicycle on top of the stuff and could still see to the back. A very versatile hauler, particularly in light of how small it is. I think the 2019's have a 2 liter engine, I would be inclined to opt for a 2018 with the 2.5 liter engine. May not be a big difference but the 2.0 will shift more and I believe it is an 8 speed auto rather than the 6 speed in the 2018 and earlier. Mine is a 2016 Titanium I bought late November of 2017. I got a very good deal on it but had to drive 300 miles to get it. Since it was Knoxville turned it into a short Gatlinburg trip at the "suggestion" of my wife. I have been very happy with mine, oil changes are not bad at all but do need to use ramps. The undercover is much easier to get off than the ones on the VW's Ive had. Under hood is very roomy compared to the VW's as well. I won't compare to the Volt as the hood on it never goes up. If it breaks I'll take it to the dealer.

depending on where the front seat backs are, from the rear hatch it is 84 to 86 inches t the back of the console. Narrowest point is just before the sliding doors and is about 45 1/2". Between the doors it is about 55" wide and maybe 50" in the back. Th rear opening height is actually a new inches lower than the roof. Attached is a photo of my 2016 TC Titanium with the rear seats folded and a WeatherTech mat in place. I like the mat as it gives me additional firming over the fiberboard pieces which bridge the gaps between the folded seats and protects the interior. I will also remove the rear seats which gives me a bit more room. Second photo is it in that configuration with a scooter loaded. Don't know what kind of conversion you are thinking about but Ive seriously considered adding a foam mattress - Amazon has three section mattresses that get good reviews and sleeping on the floor with the scooter outside. Haven't tried it yet as the last camping trip was on my motorcycle. It is faster, gets better gas mileage and is more fun than the TC. Well unless there is snow, ice or lightning.

Doesn't make much difference with the 3rd row in or out the width and length are the same. I'll look into it in the morning and let you know. I do no a 4x8 sheet of plywood will not fit. The only reason I take the 3rd row seats out is it gives a bit more headroom for hauling stuff like my scooter. Its an amazing van but which has an incredible amount of interior space considering the outside dimensions but it is still a small van.

Bearings are more standard than most folks realize. There is probably a number stamped on the side of the race or bearing. You should be able to cross reference that number and find one that is the same size and capacity. If my memory is correct all bearings are actually metric sizes and have been for a long time. Cross reference using Dr. Google the bearing expert. Usually I just go to a replacement part but on a couple of rare occasions Ive actually used the bearing numbers. Hope this helps.

your TC should run better and get better gas mileage now! My guess is the old filter had so much resistance that it tore. As for grime I would clean the intake as well as you can. If there is a lot of grime way up it I would be somewhat concerned about engine wear. If you have been driving in a not too dusty environment then probably not that much grit has gone thru the engine. IMO the biggest issue would be worn piston rings which could cause oil burning and loss of compression. It looks somewhat dark, is that from dirt? I wouldn't swap out the intake hose but might remove it and throughly wash it if that is not too difficult.

My TC lives in the garage and a couple of times this winter Ive noticed that the temperature takes a while to update. If it 55 or 60 in the garage and 30 outside it takes longer than I would expect for the temperature to update. May be the location of the temperature sensor. With a 20 or 30 degree difference its easy notice.

That will be interesting, please Ford keep VW out of your engine design. I've had three VW turbos and 2 of the 3 dies prematurely due to engine failure. The third wasn't so bad but had other issues. VW's drive nice but Ford knows how to build a turbo motor. Also have had two with the 2.5 liter 5 cylinder. Those engine are normally aspirated but have a vacuum pump for the brake booster.

I would carefully check the connection for loose or corroded connection. Not sure what the sensor type of device the sensor is but thermistors and red can be more sensitive to connection issues.

Thats a good deal. I would change the transmission fluid, brake fluid and oil but otherwise cars today are much more reliable than they used to be. Today I think if a vehicle doesn't make it to 200,000 something is wrong. If you ask the question why is a vehicle traded in? There are lots of reasons but if someone like a vehicle they usually keep it for a while. May be good logic to vehicles with some miles on them being traded for a newer one not because they are problematic. Lower mileage may be fleet or leased who knows, just my thoughts. LOL, I think I qualify as an old dude but up until last summer my primary vehicle beside the TC was a Kawasaki Ninja that could do 160. I never had it there but did have the throttle twisted all the way around many many times :-) No I'm not going to say how fast it went with me on it. I've had more shocked looks when I stop somewhere and took off my helmet, people were expecting a 20 something not a balk guy with grey hair.

Welcome to the forum. You didn't say anything about injuries from the crash so presume ya'll are all OK. I find patience is a valuable tool when looking at TC's. I bought mine over a year ago and wound up buying a new 2016 in November of 2017. The dealer came off over $7,000 so to me the difference between a nice CPO or CarMax used and the one I bought was not that great. It is a 3rd vehicle for us and we use it for hauling people, stuff and grandkids. It fantastic for elderly or people who have difficulty getting around. It is a unique vehicle that a lot of people, particularly reviewers, just don't get. It's not fast except when compared to my Honda Metropolitan, but it goes well enough. IF a dealer has a left over 2018 you could probably get a good deal on one. There might even be a 2017 floating around somewhere. Mine came from a dealer 300 miles away, I drove a VW Rabbit up and traded it in and got a reasonable amount for it. I have found Car Gurus to be a helpful site when searching for vehicles. My son recently bought a Focus ST that I fond thru them. Thru the Ford website you can see what local dealer inventories are, they limit you to a small distance around a zip code so you have to figure out the zip code for where you want to search and use that. On CarMax it seems like the mileage on a vehicle doesn't make that much difference and even the model year doesn't have as much impact as Id expect. If possible I would try and avoid higher mileage vehicles. For the TC a possible weak point is the transmission. The fluid is supposedly lifetime but like a number of other vehicles it is not a lifetime fluid. Changing the fluid on a regular basis is the key to getting a good service life out of it. For example the 2008 VW Rabbit automatic (a Japanese unit) was sold with lifetime fluid. But the fluid doesn't last the lifetime and should be changed every 50,000 to 60,000 miles. My TC only has 13,000 miles on it and has been trouble free. It is pretty quiet and the only annoying thing is the rattle from the car seats for the grandkids. Its ride is not as smooth or plush as the Honda Odyssey that my daughter has but that costs much more and is a good bit bigger without the headroom. Bought a 60" TV for mother-in-law the other day. It fit in upright with the rear seats folded down. It does handle very nicely and I'm continually surprised at how well it goes around corners. My other car is a Volt and what is surprising is how little the difference in footprint is between the two. My garage is tight with space at a premium so a small vehicle is nice. Wife's car is a Smart Car which shares space with a motorcycle and 3 scooters! She drove a GMC Safari van for many years hauling our 4 kids around and had seen the Smart cars in Europe. When they made the announcement they were importing them she immediately put down a deposit. Her second choice was a Fit. When I was getting over knee surgery due to a scooter crash she drove me around in the Smart car - surprisingly it was very easy to get in and out of even with a leg that would not bend.

I crushed part of a connector only CBR600RR motorcycle, bought a wiring harness and used the housing and one connector from it. There are some suppliers who carry the connector blocks and terminal pieces but they are hard to identify and source. It's not hard to back a terminal out, what is had is figuring out how to do it! Patience is the key.

WOW, good you got some of it fixed. Dealer should be on top of the other issues After hearing about the cut wires I'd be suspicious about something similar with the other problems. Seems like a lot of electrical issues for a vehicle that's not that old.

Not sure how it would impact the air bag performance on the passenger side.

Check all of the connectors you can find. Unplug and re-plug, a lot of the time electrical problems are connection issues. Of course the first thing to look for is a blown fuse.

Not too difficult to match the color. Problem I encountered on my motorcycle was getting the clear coat right. Most clear coats are good as long as they do not encounter a petroleum based solvent. A lot of rubbing compounds have petroleum solvents in them. My solution was 2K SprayMax clear coat. Great stuff but have to be very careful with it as the harder is a dangerous chemical. As for a clear coat it is spectacular, ver hard and resistant to gasoline. I'm not even attempting to spell the hardener as I have an engineering degree and cannot spell. :-)

For oil changes I bought a pair of Rino Ramps - Amazon I think. They work very well, can drive up on them without much effort, miss all of the plastic in front and have descent stops so I don't drive over them. They stack together somewhat for storing so take up less space. With the extra few inches the oil change is easy. I can get to all of the screws to loosen the under tray. It is the best one I have encountered. It stays in place even when the screws and two clips are removed but is easy to slide back and drop. Doesn't weigh much. Oil filter is easy to get to and is a spin on so easy enough to remove. Drian plug is also easy to get to. Only issue was pouring the oil in - had to dig out the small funnel I used on my motorcycles. I have a garage but in front of the TC is a metal lathe from the late 1800's so not much room. On the floor I put some of the square floor cushions I got at Costco. They make it easy to lay on the floor. I'm very happy with the engine bay on this car. My son had a VW Jetta with the turbo motor, very difficult to get to stuff in that engine bay.

Interesting how Ford and GM are abandoning the car market. Last week I drove over to Atlanta. Left downtown at 4:50PM - right into the heart of rush hour. What did I see? An interstate filled with SUVs? No, it was cars everywhere with some SUV mixed in. I think they have just given up on the car market because it is too difficult for them to compete with the Japanese and Korean cars. Certainly lots of SUVs are being sold but when you go into a Chevy dealership, what kind of cars do they have? Not much that interests me, Ford had a good car in the Focus but didn't stay on top of the market and keep it updated with current trends. If you look at the Honda Civic Sport it is very similar to the Ford Focus ST, the Honda Clarion is very similar to the Chevy Volt. I put the blame on poor leadership. Both Ford and GM have plenty of talented engineers and designers but WAY too many accountants and a lack of leadership with a vision. OK that's my rant for today.