Ranger/BT50 power problems and fuel economy

[caprusz]

I joined this forum today to share my findings to hopefully help others out there who may be experiancing the same problems, and don't know what to do with lack of power and bad fuel economy.
I am a 39 year old male (tradesman)
I have a ranger 2009 auto 4x4 crew cab with a few accessories with 5000km on the clock
I will try to keep it as short as possible
I thought my ute had no power when towing and on some hills 40km in 2nd was the best I could do, and 90km was flat to the boards on a hot day with a load behind of 1.5 tonne, also had bad lag
A 140km trip used over 1/2 tank of fuel that day (mannum and back)
The local ford dealer did computer checks and found nothing, but said that my ARB bullbar is causing airflow problems to the intercooler
Not happy to there suggestion to remove my bullbar completely, I dyno tested the vehicle at willall racing and found the results were 65kw at 90kph on a 24.4deg day on the 4th&5th test when the intercooler failed and 275 N.M torque
Willall racing technician told me my intercooler was no good
I found an intercooler custom manufacturer in adelaide Cross Country 4x4 ph: 08 82768569 who built a 30,000 btu cooler and upgraded the trans cooler 30,000BTU rating also for around $1300 I have photo's of there excellent work, and I have there blessing to tell others of there capabilities.

Now the car is amazing with huge power differances and power use, with the same trip using just over 1/4 tank of fuel
Town driving is from 14ish LP 100km to 11 with the 1st tank
Haven't done a long distance run yet with the new cooler.
The same hill is now climed in 4th gear at 3100rpm not 3500rpm in 2nd as previous as 3rd wouldn't hold it
I was going to chip the engine but now its not required and sent it back
New dyno tests are : 65 to 89kw at 90kph now peeking at 92kw instead of 69kw, (at the wheels) the torque is 100N.M improved also at 275-375N.M thats a 40% increase of power
Ford currently dont want to know about it and blamb arb bull bar design for air flow restriction, and ARB say this is not the case and have fitted 100's, so I couldn't be bothered with a huge fight and paid for it all myself at around $1500 by the time I did tests and tilt trays etc...

If you are having power problems or high fuel use and your dealer doesn't know why and just tells you to let it run in for another 40,000km then just feel your inlet and outlet lines on the intercooler hoses (drivers side is outlet) the outlet should be as cool as your bull bar (mine is -NOW!) and the other side is as hot as a cup of coffee if you touch the side of your cup.
Then ask them to explain why and how they intend to fix it...yeh right!!!

The only person that would be good to tell is the state rep of ford Aust GLEN as he doesn't here of any problems with any other cars like mine, but out of respect for him contact him through your local dealer, but don't expect much

It has been a frustrating time but an excellent result obtained and could only recomend to others to upgrade there intercoolers to get fuel economy under controll due to better torque and acceleration without pushing the engine so hard - especially if you are in a warm part of Australia and need to tow sometimes

I have dyno test results, and photo's I can e-mail if you want to see it or feel free to ask questions if you want
Hopefully I dont get 100's of replys but who knows??

craig

[DamTriton]

Thank you for the detailed insight.

[caprusz]

Actually if you have or are experiancing the same problems that I talked about and your vehicle is genuine inc the genuine bull bar can you just drop me a note!, so I can get up the rep myself

caprusz

[peter_sam]

Actually if you have or are experiancing the same problems that I talked about and your vehicle is genuine inc the genuine bull bar can you just drop me a note!, so I can get up the rep myself

caprusz

To caprusz,

I have had exactly the same experience! In July this year I traded in a 2007 manual PJ Ranger for an automatic PK Ranger and I ordered an ARB bullbar for the new vehicle. I had an ARB bar on the vehicle I traded and I never experienced any problems with it. Anyway, as ARB hadn't manufactured a bar for the new PK ranger I put the bar on order and drove the vehicle for around 3 to 4 weeks without any noticlable problems although I did take it easy with the car. The ARB bar was fitted when the vehicle reached around 1000kM and after it reached 1500kM I attempted to tow a trailer up a hill and couldn't go over 20kmh - 30kmh!! I dropped it back manually to second, but no improvment - the vehicle was just plain gutless and fuel economy was horendous! I complained to Ford and after a couple of days they told me that they believed the ARB bar to be the problem in not letting enough air into the engine and suggested fitting a snorkel and/or contacting ARB. I made contact with the ARB dealer who just said that they fit lots of bars and that it was Fords problem but he would phone me back. I was sceptical about the air issue but thought the ARB person's attitude was just plain arrogant! I contacted TJM and got a quote for a snorkel and had it fitted and I also had a chip put in at TJM and it now goes quite well (their quote was marginally less than ARB) - the car goes how it should have gone in the beginning. I am quite annoyed by the stance taken by ARB on the issue and when he did eventally phone me back a few months later it was only to see if I still had a problem and could I infer to the Ford manager that the ARB bar was OK!!! As if I would do that !!! ARB have lost me as a customer!!

Also last week I booked the Ranger in for its 10000 km service and the service guy said another Ranger (automatic) government vehicle fitted with an ARB bullbar was experiencing the same problem and ARB fitted a snorkel and the problem with power and excessive fuel consumption was solved so it would appear that's now 3 vehicles with ARB bars I have heard of that have had the same problem.
I did find interesting is that you had the intercooler modified and although I am reasonably happy with the cars performance now but there is always room for improvement when towing.

[pmturnbull]

just wondering are you still getting good fuel usage around town the best I have got from my bt50 auto has been 11.92 (with my tools onboard to). when you also said the intercooler failed whats that mean.

[caprusz]

peter! interesting the snorkel has made a differance! my dad doesn't tend to have much trouble with his but he had a snorkel fitted when he bought his bt50

I asked him to feel his inlet hoses when he got to his destination last week and he said the hose was quiet warm but the other was hotter

So in my opinion on a day like today I recon he would have been in trouble if he was to pull 2.5tonne in this heat

I Pulled my boat from mt gambier today at 43deg I think it was and it went well, it is about 17 - 1800 kg and 110 was the speed most of the way but had to let it go to 100 a few times or rev it out which uses more fuel
I did have a side and slight head wind also and used 60l to go from naracooorte to adelaide which I think is ok as my old ranger did the same but thats not with a boat on the back and at night (petrol)

I did feel my tank on the inlet to the cooler several times and it was only slightly warm but the other side I was not silly enough to touch as it would be sooo hot...if the hoses were anything to gauge when I touched them.

So the best check is to check your tank on the drivers side, if it is too hot to touch then your cooler is no good!

I didnt chech the hose temp as when I stopped I had been sitting for a while with the air on!

To pmturnbull: I have been on holidays for 3 weeks now and back in 1 more week so I will let you know about town fuel usage later on!
As for intercooler fail - if it is too small it will not cool the exhaust gas quick enough to compress the air enough to work at its best capacity
so the cooler the air on the tank in-side, the more boost from the turbo
So if its like mine was then I was suffering a 40% power loss, the intercooler wasn't doing its job, but it does now! but I am also interested in what peter mentioned about the snorkel as an additional air restriction problem so I will look into that also as air comes from the L/H guard area

thanks craig



I

[caprusz]

just a correction ! my old ranger is actually a 2000 rodeo v6 petrol

Also peter I don't understand how a snorkel would make much differance as the air intake is in the left guard and how will a bullbar change the airflow in this area? but if it helped you good stuff! but maybe its the chip that has helped you! if you had it fitted at the same time?what type did you use?
I would also suspect your intercooler is still suffering from a lack of direct airflow as they need flow to work unless you upgrade it! if you fit a bullbar
check your hoses and intercooler tank as you might be masking the power problems with a chip, so it would be so much better with a decent cooler and not know it yet

I don't need to talk you into it if the hoses are really hot then the cooler isn't doing its job and has to go! my dyno charts show the results before and after

craig


craig

[caprusz]

just wondering are you still getting good fuel usage around town the best I have got from my bt50 auto has been 11.92 (with my tools onboard to). when you also said the intercooler failed whats that mean.

I filled up today, the 1st since my holidays and fuel usage was 13.1 L per 100km for town running.

So happy with that!
craig

[pmturnbull]

thanks mate I have disconnected the egr a couple of times and the power increase with lower intake temps can be felt just driving so I will be looking in to the intercooler upgrade for sure. $1300 was that for both autobox and intercooler price.

Does anyone else experience there auto not dropping back to 3rd or 2nd and trying to carry 4th gear even though your doing 30km up hill and trying to perform a rolling start from round about or lights. Alot of the time I manually pull it back into 3rd to get it going. I filled in my mazda service report card and complained about this and someone from mazda HQ rang me (surprised) and says it dosen't sound right and to take it to the service centre to have it looked at but just wondering if it is just a normal function of this gearbox.

[caprusz]

thanks mate I have disconnected the egr a couple of times and the power increase with lower intake temps can be felt just driving so I will be looking in to the intercooler upgrade for sure. $1300 was that for both autobox and intercooler price.

Does anyone else experience there auto not dropping back to 3rd or 2nd and trying to carry 4th gear even though your doing 30km up hill and trying to perform a rolling start from round about or lights. Alot of the time I manually pull it back into 3rd to get it going. I filled in my mazda service report card and complained about this and someone from mazda HQ rang me (surprised) and says it dosen't sound right and to take it to the service centre to have it looked at but just wondering if it is just a normal function of this gearbox.

Intercooler and auto trans cooler was fitted to mine for that price but talk to grant at cross country 4x4, south road adelaide, and he should know what the current price is..do mention my name (craig with ranger)
A fellow walked into my workshop today to ask how my ranger was going as he was experiancing performance issues on hot days and he had a bt50 auto with a genuine bullbar....I guess it was his lucky day to pick me of all people (-: to help him and show him all in one hit!
He is getting his fixed now! and his ute is 12 months old! and yes paying for it himself! crap eh!
I used to have auto kick back problems before I had my intercooler and transcooler fitted, you go up a hill and it wouldn't go back to torque converter lock up and I used to pull it back to 3rd to go up large hills and keep the revs above 3000-3200 or it would die and only go back in gears at 2500 or so if I left it up to the trans to do it all!, also if I let the gear box do it all when I put my foot down harder you could actually see and feel the rpm DROP 150rpm
Strange but the dealer told me thats normal and called it turbo lag!
WHAT A LOAD OR RUBBISH!!!
I don't have it now, but I don't know if the intercooler or the transcooler fixed it, but its a different car. with power at 2200-2500 range with converter lock up and trans working as it should (-:

May not be what you are experiancing though?? Try talking to an auto trans specialist like norwood transmissions as dealers often don't know much!

If you want I can ring you, just email me your ph no. cajmail@bigpond.com
By the way whats egr?

craig

[caprusz]

thanks mate I have disconnected the egr a couple of times and the power increase with lower intake temps can be felt just driving so I will be looking in to the intercooler upgrade for sure. $1300 was that for both autobox and intercooler price.

Does anyone else experience there auto not dropping back to 3rd or 2nd and trying to carry 4th gear even though your doing 30km up hill and trying to perform a rolling start from round about or lights. Alot of the time I manually pull it back into 3rd to get it going. I filled in my mazda service report card and complained about this and someone from mazda HQ rang me (surprised) and says it dosen't sound right and to take it to the service centre to have it looked at but just wondering if it is just a normal function of this gearbox.

Intercooler and auto trans cooler was fitted to mine for that price but talk to grant at cross country 4x4, south road adelaide, and he should know what the current price is..do mention my name (craig with ranger)
A fellow walked into my workshop today to ask how my ranger was going as he was experiancing performance issues on hot days and he had a bt50 auto with a genuine bullbar....I guess it was his lucky day to pick me of all people (-: to help him and show him all in one hit!
He is getting his fixed now! and his ute is 12 months old! and yes paying for it himself! crap eh!
I used to have auto kick back problems before I had my intercooler and transcooler fitted, you go up a hill and it wouldn't go back to torque converter lock up and I used to pull it back to 3rd to go up large hills and keep the revs above 3000-3200 or it would die and only go back in gears at 2500 or so if I left it up to the trans to do it all!, also if I let the gear box do it all when I put my foot down harder you could actually see and feel the rpm DROP 150rpm
Strange but the dealer told me thats normal and called it turbo lag!
WHAT A LOAD OR RUBBISH!!!
I don't have it now, but I don't know if the intercooler or the transcooler fixed it, but its a different car. with power at 2200-2500 range with converter lock up and trans working as it should (-:

May not be what you are experiancing though?? Try talking to an auto trans specialist like norwood transmissions as dealers often don't know much!

If you want I can ring you, just email me your ph no. cajmail@bigpond.com
By the way whats egr?

craig

Also ford tested a genuine vehicle the other day with 75deg intake temp and one with a bullbar that had problems, at 114 deg, so if you think you don't have problems and you have a bull bar ....good luck
I told them to get there client to call me but nothing! shame!

[pmturnbull]

thanks mate for the ofter egr is the exhaust gas reticulation this adds at least 20-40 degrees to normal intake temp on my scangauge. I normally have around 80 to 105 intake temp with it on and with it disconnected lucky to go over 60 unless big long hill and towing. Only problem puts fault light up on dash. The other thing is I never seem to get great miles to the gallon with it dissconnected either I always am doing city driving when its disconnected or driving it harder and enjoying the power.

[caprusz]

thanks mate for the ofter egr is the exhaust gas reticulation this adds at least 20-40 degrees to normal intake temp on my scangauge. I normally have around 80 to 105 intake temp with it on and with it disconnected lucky to go over 60 unless big long hill and towing. Only problem puts fault light up on dash. The other thing is I never seem to get great miles to the gallon with it dissconnected either I always am doing city driving when its disconnected or driving it harder and enjoying the power.

Thanks for that!
I just did my first oil change last week at 10,000k/m and found out that the dealers use Mobile 1 5w/30 semi synthetic at $30 a bottle but charge $65
I used mobile 1 FULLY SYNTHETIC 5w/30 at Trade just under $70 but retail $90, and it takes 7 litres, so will cost you 2 bottles for the 1st one.
A good idea to remove all guards not just the rear one! I discovered!

This was Mobile technical recommendation as the best!

The engine doesn't have the occasional metalic rattle as much,under acceleration, so maybe it was the crap genuine oil! Gee it was black!
Mobile also boast excellent fuel economy with there best oil, so we will see.
Even though i am not bothered too much about that!
craig

[pmturnbull]

just wondering are you running a scan gauge and what temps does your intake temp run at now.

[caprusz]

just wondering are you running a scan gauge and what temps does your intake temp run at now.

No mate just going off the details given to me by cross country 4x4 whom have done these tests before!

craig

[philaine]

Thanks Craig had my Ranger PK auto dual cab done today at Cross Country 4X4 cost $1400, I also had an ARB Bull Bar fitted prior to delivery, Ford didn't advise me against it, I was towing a 2000 kg 18'6" van up a steep hill (Sheperds Hill Road) and was down to 20 kmh in first gear (auto) and was passed by a STA bus. I had a snorkel fitted from the start, this didn't help me at all. The job at Cross Country took a day, their workmanship was excellent. I have noticed the power straight away and the temp gague is showing a little cooler.

[TinyGQ]

Hey there everyone, just reading this post i thought i would post about my ranger. Just thought id mention that i have an 08 ranger manual with a snorkel and TJM bullbar with winch that completely covers the intercooler but doesnt seem to affect performance at all? I tow a dingo around most days and i thought the power was really good. So could it just be a dodgy cooler? I was actually thinking of putting a decent cooler behind the grill as the tiny ford one is completely covered by the winch partly for a bit of wank value cause i thikn it would look fcukin awesom and also thought there might be some power advantages, now im thinkin it might hammer when i do it! Also even towing all the time i get around 12l / 100. Could it be an auto thing?

Anyway just thought since i have a winch covering the cooler id let you know mine seems fine so the bullbar excuse counds like bullsh*t.

[philaine]

I think it has to do with the 2009 (PK) Ranger model, I think that the intercooler may have been reduced in size or is in a different position. The Auto trans cooler is smaller than ones fitted to Suzuki's. I towed my caravan to Port Broughton and back and was using 25litres to the 100 km. so I'm hoping for a vast improvement, time will tell. I'm not towing for a while but I'm driving to Darwin soon so should know a bit more after that.

[caprusz]

I think it has to do with the 2009 (PK) Ranger model, I think that the intercooler may have been reduced in size or is in a different position. The Auto trans cooler is smaller than ones fitted to Suzuki's. I towed my caravan to Port Broughton and back and was using 25litres to the 100 km. so I'm hoping for a vast improvement, time will tell. I'm not towing for a while but I'm driving to Darwin soon so should know a bit more after that.

Glad to here it has helped...and my experiance has been able to help you as I had to do it all on my own with no facts to back it up!
remember its good to open up the slott in the bash plate to get max air flow, just cut it from 20mm deep to 50 with a angle grinder Off the ute!

Tiny GQ
ARB has sent a pk ranger to Cross country 4x4 a few weeks ago as its having problems with power so I think that speaks for its self...it was a gov vehicle also!
Also my intercooler was tested by ford Aust, it took 6 weeks to get it back and they said there was nothing wrong with it, I do feel that the Auto does struggle more with this problem, however my dad is having his manual mazda done this week! He pulled up Palmer hill with a van, and stopped at the top to feel his hoses and they were hot enough that you couldn't leave your hands on it so for additional Boost, cooler intercooler temps = more power, he thinks it has to help....lets face it! if the intercooler is 70+ deg on the outlet you are loosing power...
Airflow is also usefull as the more airflow the cooler you can maintain the cooler, and I had a fellow call me who put a bullbar on his vehicle 2 months after purchasing his ute and the vehicle died with no power, I don't understand why it is only on a few utes but as I have been saying all the time.....feel the hoses.....it there too hot.....the intercooler is not working as good as its supposed to be....load + hot day + working ute hard and hoses hot on the drivers side
then thats a good reason in changing intercooler,
Hoses cold then don't waste your cash!

For all others out there with issues cross country 4x4 are in the process of producing Kits suitable for do it yourself installation

Please keep posting you stories with your outcomes as its good for others to read the outcome of YOUR FACTS!!

craig

[spottydog.]

For those of you in SE Qld, Northside 4x4 at Caboolture also do a kit for the BT-50.
They fitted a larger intercooler, exhaust, K & N filter and snorkel to mine and the difference was amazing.
Heaps more power.
You can see the kit here

[philaine]

Just returned from a trip to Mildura, did 984 kms on 120 liters of diesel since the installation of the larger intercooler. before the change over on the same trip I only got 749 kms on 122 liters of diesel. i have a 126 litre fuel tank.

[caprusz]

Just returned from a trip to Mildura, did 984 kms on 120 liters of diesel since the installation of the larger intercooler. before the change over on the same trip I only got 749 kms on 122 liters of diesel. i have a 126 litre fuel tank.

Great news!

PK RANGERS AND MAZDA BT-50

A fellow rang me the other night to thank me for the time I spent to help him, he smashed his genuine bumper and was forced to go aftermarket due to genuine not being available...ARB told him to call me (-: and he went to cross country 4x4 as I recommended, and was SO HAPPY with the result and told me a 90km hill he did at 119k/h and stopped accelerating..
no flat spots anymore and a smoother trans he said! new ute!
Great stuff
My father inlaw fitted one to his manuel and used to sit on 100K/M with a van and was impressed with the additional power and said he looked down and was on 110 and wasn't pushing it..

Feel your hoses people

And please post your good news to help others

caprusz

[01lux]

Very intresting as i work for mazda and have never really seen any dramas with the intercoolers.
There is a bullitin about auto bt50's with aftermarket bullbars causeing the transmission cooler to over heat due to insufficant air flow,you may have to speak to the dealer to find out more info.

As for lack of power, try removing the boost sensor(located on the top of the inlet manifold,black sensor with 1 bolt.easy to find) and check to see if it has carbon deposits on it, if it does clean it with electrical contact cleaner and refit. aslo when your at the dealer the next time get them to reset the MAF sensor,will result in better fuel economy.

If you have any questions feel free to ask.

[caprusz]

Very intresting as i work for mazda and have never really seen any dramas with the intercoolers.
There is a bullitin about auto bt50's with aftermarket bullbars causeing the transmission cooler to over heat due to insufficant air flow,you may have to speak to the dealer to find out more info.

As for lack of power, try removing the boost sensor(located on the top of the inlet manifold,black sensor with 1 bolt.easy to find) and check to see if it has carbon deposits on it, if it does clean it with electrical contact cleaner and refit. aslo when your at the dealer the next time get them to reset the MAF sensor,will result in better fuel economy.

If you have any questions feel free to ask.

Thankyou for your advice and I will definately look into it
Also my ute was guttless from brand new, with the bull bar fitted
Another fellow had to wait for 2 months for a bullbar to come in and when his was fitted his ute just died!!! new intercooler fixed it.
I have had at least 8 people contact me with the exactly same problems and issues that are now fixed with a decent size cooler
The state rep of ford australia Glen waved all responsibility of AFTERMARKET attachments "quote" they do not test vehicles for aftermarket compatability.......so can not be responsible for issues they may cause..
Also the bull bar manufacturer says they have flow testing to show there is no issues with there bullbars, but they also refer people to ME!! as I can guide them with there trouble (funny eh!) no one takes responsibility
THIS IS WHY I HAVE SPENT SO MUCH TIME TO WRITE ALL OF THESE REVIEWS
JUST TO DO THE RIGHT THING FOR SOMEONE ELSE< as no one would help me...

Thankyou so much for writing back and I will definately look into the boost sensor and get the maf sensor reset!
I really appreciate your input
Is a reset something that I can do or do you need a computer?

craig .......cajmail@bigpond.com

[01lux]

The maf reset has to be done by mazda or ford.

[caprusz]

The maf reset has to be done by mazda or ford.

Thanks 01lux

I checked out the sensor and it had quite a bit of carbon on it but to be expected in the exhaust manifold I guess, and cleaned it up in a few seconds but didn't notice anything different, but thats ok..
contacted ford and they didn't know what the maf reset was so I told them they have 1 week to find out and I will talk to them next week about this

Thanks again for your help........appreciate it

craig

[01lux]

Exhaust manifold ?? you mean inlet?
The boost sensor is on the inlet manifold.

[caprusz]

Exhaust manifold ?? you mean inlet?
The boost sensor is on the inlet manifold.

Yes you are correct (drivers side)....unclip the harness, remove 2 nuts to lift a bracket up a bit so you can get a spanner to the 1 bolt
(10mm I think it was?) that holds down the sensor

A small black plastic thing that is the size of 1/2 a match box with a pen size sensor on the end of it with lots of black muck on it when you gently guide it out of a small hole that is.
This is it isn't it??

craig

[01lux]

thats the one!

[pmturnbull]

I spoke with mazda about maf reset they know nothing about it and they told me they cleaned because it had muck on it.