P2096 - '12 3.5 eco f150

[samw3002]

Former Ford SMT here, this code can be a nightmare to chase down, a couple of suggestions for you.
1. Since it only happened since the exhaust was modified, I would tape off the air inlet and find a way to pressurize the exhaust at the tailpipe and spray soapy water to all the welds and joints..a small pinhole leak will cause this code. Chased my tail on a brand new 3.5 EB Explorer only to find someone didn't weld all the way around a cat seam.
2. Also seen thus caused by a leaking cannister purge valve....easy ck by removing and try to blow through it.
Good Luck!

 

[DSG2003Mach1]

Former Ford SMT here, this code can be a nightmare to chase down, a couple of suggestions for you.
1. Since it only happened since the exhaust was modified, I would tape off the air inlet and find a way to pressurize the exhaust at the tailpipe and spray soapy water to all the welds and joints..a small pinhole leak will cause this code. Chased my tail on a brand new 3.5 EB Explorer only to find someone didn't weld all the way around a cat seam.
2. Also seen thus caused by a leaking cannister purge valve....easy ck by removing and try to blow through it.
Good Luck!

thanks, hopefully I don't have to chase this any further but good info to have!

I really think it was keeping the crappy crush washers on the non-foulers allowing it to leak. I took them out (the non-foulers all together) Sunday afternoon and so far so good with no current or pending codes

 

[DSG2003Mach1]

Even in the vice you can’t get them to crush evenly so if you ever needed them I’d say toss the that part

 

[DSG2003Mach1]

I'm gonna consider this resolved as the non-foulers causing a leak. I've put over 1,500 miles on it since removing them and no more codes of any kind. Truck gained back a little over 1mpg on the highway since replacing the cats. I had marked up the MPG loss to the leveling and tires but apparently that wasn't the sole cause.