I am just through replacing the catalytic converters on an 06 Ford Expedition with about 151k miles on it. To break in new cats, you must run it at idle for about 5 minutes, then increase the engine speed to 2500 for two minutes.
I broke the cats in just fine, then let everything cool down for about 15 minutes. I took it out for a drive of about 5 minutes. Everything seems fine. When I got it back to the house, I parked the truck and while sitting, tried to rev the engine up, but it would only go to 2500 rpm (well maybe just a little over it). It acted like there was a engine rev limiter keeping it at this speed (bounced a little above/below) for about 10 seconds, the settled out to an even 2500 rpm even with the pedal planted on the floor. I thought there might be an issue with it, so I took it out for a drive again. I nailed the accelerator and it hopped right up past 4500 rpm without an issue.
The question is: Is this normal behavior for Ford vehicles with drive by wire? Or maybe just for Expeditions? If it is, has Ford given a reason for programming their vehicles this way? Personally, if I want to rev my engine to the moon, I want the system to allow me to do it. Only allowing the engine to rev to 2500 makes me think there are other issues with the vehicle.