i have an 03 f250 and have had the run around on it for the last year and a half.. i was told i had 2 injectors bad, egr bad, and high pressure oil pump was bad. paid and had all that fixed and truck still does the same thing. it wont start half the time, when idling it sounds as if it were missing and wouldnt pull the hat of you head. i am lost. can some one please help me..

 

Look into the ICP sensor. I can't take credit for this post but good information, good luck...

Many different causes for surging:

ICP sensor and/or pigtail
Stuck turbo vanes of worn out turbo center section
Turbo VGT actuator
EBP sensor
IAT2 sensor
Sticking IPR valve
Clogged or failed EGR valve
Injectors
Possibly FICM

Help 2004 6.0 Surging - Diesel Forum - TheDieselStop.com

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An ICP sensor concern will cause RPM surging and at any speed. Usually it is at random and can vary as far as intensity is concerned. The sensor itself may be the problem however poor connections due to the sensor connector will also cause erratic RPM changes. Being a 2004 model I question if this truck is an early build with a 2003 level engine that has the ICP sensor mounted on the High Pressure Oil Pump (HPOP). THe ICP sensors on those engines have a high failure rate. Typically the sensors literally come apart causing erratic signals AND they leak engine oil. The oil not only makes a mess but it also ends up in the harness requiring replacement of the sensor harness connector.

If your surging is more noticable at cruise I might suspect a turbocharger issue, specifically with the unison ring that controls the vanes. A worn control lever slot will cause a cyclic surging under light throttle and stready throttle operations.

A simple data recording made during a road test will usually pick up something like this provided the truck exhibits the concern.

 

it really never surges the rpms high. it just basically runs like crap. i mean seriously will not get out of its own way. it acts like it has a spark plug wire off but i know it dont bc it dont have spark plugs. lol

 

When was the last time you changed fuel filters? Maybe a fuel delivery problem....

 

Again, just info I found, I cannot take credit.

Rough idle issues, rough running motor, loss of throttle peddle and bucking, not starting, high to low idle then no power, motor was shaking, etc.:

I have seen several trucks with the exact symptoms you describe. When I was able to actually experience the concern, I found that the ICP pressure reading from the ICP sensor was very erratic and would sometimes read 1100psi with the key on engine off. These trucks (and one van) would sometimes set a code P0299 (turbo underboost) after the "dead" pedal symptom occured. Replacing the ICP sensor and connector has cured all of them.
A chaffed wire at the EBP connector is also fairly common and can cause similar symptoms on later model trucks that have the EBP sensor located by the left cylinder head, underneath the coolant resevoir. That chaffe is pretty easy to spot.

 

only code it has thrown was crankshaft sensor and i replaced it. and i replace my fuel filters every oilchange.

 

Moved to the 6.0L Powerstroke Diesel forum.

 

Check for wire chaffing as suggested. Also, what is your answer on fuel filters (and oil changes also)?

Since the surging is at lower RPM's it doesn't sound as much like the IPR. If they replaced the HPOP and didn't look over the ICP and harness closely then what a huge shame!

Look up FICM testing and check its voltages also.

 

They replaced the icp

 

Any other parts replaced recently not mentioned in original post?

 

Has anyone ever heard of moisture seizing up the turbo and having to rebuild it? Also on the turbo seizing up I was told I wasn't driving it enough.???

 

Also on the turbo seizing up I was told I wasn't driving it enough.???

 

The turbo seizing up from not driving it seems to be somewhat common, but i havent heard about it much though

 

That is true, moisture gets in the turbo and causes rust and if you are not exercising the turbo enough by driving it the unison ring and vanes will start to bind up.

 

My 2003 has 94k on it. How much is enough to keep this from happening again? Anything I can add to fuel to stop it?