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04 Ex sudden loss of all engine power, sputter, then runs fine?

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Old 03-12-2012, 01:00 AM
UNLIMTD UNLIMTD is offline
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04 Ex sudden loss of all engine power, sputter, then runs fine?

Hello all, I recently purchased a 2004 Diesel Excursion with 220,000 miles on it. I feel that I got a great deal and am headed into this knowing that I will be putting some money into it soon. I want to “Bulletproof” it, but I am hoping that can wait until next spring.

I changed the oil to Rotella T6 5-40, and used a product called Hot Shot’s Secret to help remove any “stiction” and cleanup the injectors.
I also changed both fuel filters and added the blue spring upgrade. I did not do the banjo bolts as they were not in stock.

**My problem:
Occasionally (4 times in 3 weeks) it will lose all engine power for a few seconds; this is while moving, and sometimes while accelerating. Today I was driving home from a 400 mile trip and halfway home it sputtered and came back to life a few seconds later. The cruise was on and it kept right on going, I did notice a large quantity of white smoke out of the exhaust. That did work well to clear some of the traffic around me, but not comforting. I was going a set speed on level ground, 75mph @ 2,200RPM.

**Supporting information:
The engine seems to have good power, and does not blow any smoke (normally).
It does stumble some when first driving it even after letting it warm up for 10 min. That does seem to be getting better, maybe just a placebo…
Fuel mileage is only about 16mpg. My previous 2004 Diesel Excursion was constantly 20mpg.
Stock tire size, and sagging springs for increased fuel mileage.

**Hypothesis
I have heard a lot about the FICM, and wondered if that was possibly the culprit.

Thank you all for your help as I have seen the wealth of information here and plan on adding to the knowledgebase when I am able.
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Old 03-12-2012, 01:32 AM
ddivinia ddivinia is offline
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Cam sensor?

My f-250 with th 7.3 had that issue. Would die going down the road, ec.

D.
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Old 03-12-2012, 01:47 AM
UNLIMTD UNLIMTD is offline
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Cam sensor, interesting, would it immediately die, and them start up by itself again? Not that all of the symptoms would match, just looking for as much info as possible before I throw money at it.

I was thinking about the fuel pump, it would cause the symptoms I am seeing.
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Old 03-12-2012, 07:48 AM
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Check the message "My Excursion is Hurt" on the front page today. Sounds like a very similar fuel pump issue.
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Old 03-12-2012, 10:34 AM
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Unless you have an AE, I would start with the usual suspects:

-You may have a leaky ICP sensor. If your truck is a late '04 truck this is something easy to diagnose. If you look on the passenger side valve cover, next to the GPCM (silver box with a black and green connector going to it), you should see a sensor with a pigtail going to it. Unplug this sensor and see if there is any oil coming up through it. If there is, replace the sensor and the harness. Drive the truck and see if the issue persists

-If you've noticed the truck having hard starts, idling rough, or not making power like it used to, you may want to test your FICM voltages to make sure it's not failing. http://www.ford-trucks.com/forums/89...procedure.html Make sure your batteries are also in good shape, a weak or dying battery can kill/damage a FICM.

The white smoke you're seeing is unburnt fuel due to the engine stopping and suddently catching itself, while not being able to burn that fuel. My educated guess would be the FICM or ICP.

If you have someone near your with one an AE it would make a world difference in getting this diagnosed and fixed. Riffraff Diesel: AutoEnginuity Total Ford Enhanced Bundle

Regardless, give the aforementioned a try and let us know what you come up with...
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Old 03-12-2012, 08:47 PM
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font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--> I had previously bought a Cheap Bluetooth OBDII tool and the torque app for my Android phone. I looked at it today and it had extended properties for a Powerstroke. I loaded them up and came up with this.

The FICM I believe is bad, 13~13.5 while driving, and it drops to 12 when starting.


FVP - 13.5
FPM - 49.0
FLP - 13.5
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Old 03-12-2012, 09:13 PM
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I'd say it's toast. Mine did the same thing.

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Old 03-12-2012, 09:21 PM
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you better replace that thing quick, fast, and in a hurry!

If you have the cash laying around, I'd look into swamps 58V FICM with a PHP FICM tune for better fuel economy and power.

hardRESET went through this same thing except his truck just wouldn't start: http://www.ford-trucks.com/forums/11...-problems.html

If you choose to stick with the stocker you could go to FICM Repair.com - Your Source for FICM Repair
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Old 03-12-2012, 09:21 PM
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you better replace that thing quick, fast, and in a hurry!

If you have the cash laying around, I'd look into swamps 58V FICM with a PHP FICM tune for better fuel economy and power.

hardRESET went through this same thing except his truck just wouldn't start: http://www.ford-trucks.com/forums/11...-problems.html

If you choose to stick with the stocker you could go to FICM Repair.com - Your Source for FICM Repair
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Old 03-13-2012, 11:42 PM
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Well I misunderstood the voltage readings I was seeing.


I thought that might be the case so I followed the procedure to test with a multimeter today. The FICM should be fine, it only dipped to 48 when it was cranking and then went up to 49 and stayed there.


I will check the ICP.


While I was in there I found this wire that has an end on it, but nothing connected to it. I looked around and did not see anything that it would go to. Any ideas as to what it would connect to?
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Old 03-14-2012, 12:03 AM
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I checked the ICP(please verify that is the ICP in the picture)it was clean and dry.
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Old 03-14-2012, 01:30 AM
UNLIMTD UNLIMTD is offline
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I pulled the EGR, and found it was a complete mess. Not dry and sooty like it should be, is this an indicator of the oil cooler leaking?


I cleaned it up as best I could, vacuumed out the hole and re-installed it.
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Old 03-14-2012, 09:06 AM
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GOOD GOD!!!!

That thing is NASTY!

If I'm not mistaken, that looks like the early signs of the EGR cooler leaking due to the oil cooler slowly but surely clogging.

Does your truck spend time idling?
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Old 03-14-2012, 10:31 AM
UNLIMTD UNLIMTD is offline
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I just bought this Excursion about a month ago. I don’t have any history; I do let it warm up for about 10 min in the mornings. I expect that you are referring to much longer idling than that. I do see some oil in the valley, on what I believe is the oil cooler. I knew that before I bought it, but like I said in the original post, I felt I got it for a good price and expect to put a new Oil Cooler, EGR Cooler, Studs, and Head gaskets on it. I was hoping that it would not be too soon.
As far as I am aware I do not have any signs of head gasket issues yet. Maybe I should just do the Oil Cooler and EGR Cooler. This is more of a long term concern, and I am hoping it can wait until summer.
This engine does have 220,000 miles on it.
Any idea on the wire that is just dangling there?
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Old 03-14-2012, 12:15 PM
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No clue on that wire, still trying to figure it out myself...

From the looks of things, you're ok....for now; but the clock is ticking...
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