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Discussion Starter #1
I have a 2002 3.8 with 130k miles. The only performance mods are a cheap CAI and divorced duals Flowmaster gt catback exhaust.

Under acceleration, (almost always light acceleration) it has an intermittent bucking/hesitation problem. I have replaced my EGR valve,fuel filter,DFPE sensor and plugs/wires at about 80k.

The only known problems are cracked header and corroded battery cables to the point where it is getting acid build up under the rubber.

Should I start with replacing the cables and could this be an electrical problem?
 

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Discussion Starter #4
I do all my own work, just wish I had someone that could pinpoint the exact problem. Without codes this is tricky. At idle it is very smooth and this hesitation is completely random, comes and goes. I have never had to replace a coil pack, can this lead to random hesitation and no codes.
 

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iPoopke Regular
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Bad coil pack can definitely lead to hesitation. Before replacing coil pack, pull all your plugs and make sure are properly gapped. Make sure the wires are all pushed on completely until the audible click. Then do the coil pack if the hesitation persists.
 

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I'd recommend new Motorcraft coil and clean the MAF. Also new wires and plugs if not already done.

It looks like you have replaced most of the EGR parts. That would be the other place to look.
 

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seafoam your car, change plugs, wires, possibly new coil pack, replace header, replace battery and terminals, if you have known problems why havent you taken care of them? problems only lead to more problems if you're proactive about things then they won't pile up or lead to even more problems.
 

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Discussion Starter #12
Thanks for all the suggestions. I think I will go ahead and tackle the known problems first.

I am going to oil my filter, clean my MAF and start redoing all my battery cables. Corrosion built up inside the rubber can't be good for anything.

Anyone know of a good how-to on battery cables. I know how to change them but was wondering if we can fabricate our own from Universal cables from walmart instead of the high priced set from the dealer.
 

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Just Cheesin'
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Is your fuel filter clogged?
Do you here clicking when it happens?

Don't spend money on cables, clean them ASAP.
Don't get plugs, wires, and coil pack. You are getting spark and it sounds like you are not getting a misfire.
Not an air filter. It would drive worse at higher RPMs and set codes.
Not the IAC because you are using the throttle, and obviously not idling. it would idle like **** from the IAC being bad.
Not the MAF, that would set a code.
Likely not the TPS. You would have a dead spot in the throttle.
No need to break out a multimeter. Electricity is going to have nothing to do with a hesitation.

When was the fuel filter changed?
 

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Just Cheesin'
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seafoam your car, change plugs, wires, possibly new coil pack, replace header, replace battery and terminals, if you have known problems why havent you taken care of them? problems only lead to more problems if you're proactive about things then they won't pile up or lead to even more problems.
All those issues have nothing to do with the hesitation. please don't bash him. He may not have the funds to fix those issues.
 

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Just Cheesin'
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Also maybe clean the injectors. I usually remove them and send them off to Witchhunter
performance,
Which is a waste of time. All they do is soak the tip in solvent for an hour and blow air through it backwards.
 

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Discussion Starter #17
I just changed the fuel filter. Should I be looking at a fuel delivery problem?
 

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Discussion Starter #19
Automatic.
No clicking. Here is exactly what it does.

Idle revs are perfect. Purrs like a kitten.
Hard acceleration very rarely hesitates.
Medium acceleration hesitates like a bitch.
Very light gas sipping acceleration very rarely hesitates but when it does it will buck until I let off gas and get back into it.
When it starts to hesitate if I let off and get back into it, it usually goes away.

Btw, thank you red, you have been very helpfull so far. I really want to get this running right again so I can start my mods back up on it. I really dont feel like modding my pontiac to much
 

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I disagree red pony - My MAF dogged on me and did not set off any codes whatsoever.
 
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