I am pretty much out of ideas what is the issue with my truck. But here it is.
2004 F-350 6.0L late build - no
Back story

Started to get coolant pukage and had over 16psi pressure. Tore down the engine and found the PO used black onyx gaskets. Already had studs. Had heads machined and put everything back together. Truck ran great before the build. This is where the fun begins. No STC fitting.

Issues

Trucks starts up no problem hot or cold. Runs great when the truck is cold. Has tons of power. Once the <acronym title="Engine Oil Temp">EOT</acronym> gets above 120F it falls flat on its face. It runs really rough, lopes and misses and shakes the whole truck. It has absolutely no power. It will not rev. above 1500RPM in drive but will rev. no problem in neutral or park. In drive the truck will barely move. Has no boost either. Truck does not smoke at all. A slight smell of unburnt diesel but that's all. At first I was getting contribution / balance codes. No the same code back to back other than #5 and no more than 2 at a time. Replaced #5 injector but still randomly getting #5. I could start truck, pull codes, reset, turn off, start the truck again and have a different code each time. Totally random. I loaded up my SCT Extreme street tune and truck acts the exact same way expect I do not get any codes.

TLDR - truck runs great cold, but horrible when warm. Seems to be temperature related.

Attempted solutions and PIDS.

Double checked push rods and rocker arms. All good.
Replaced #5 injector. Code still randomly comes up.
Replaced <acronym title="Injection Pressure Regulator">IPR</acronym> valve - connector on <acronym title="Injection Pressure Regulator">IPR</acronym> broke during build
Replaced <acronym title="Injection Control Pressure">ICP</acronym> and pigtail. <acronym title="Injection Control Pressure">ICP</acronym> builds under <acronym title="Wide Open Throttle">WOT</acronym> correctly.
<acronym title="Injection Pressure Regulator">IPR</acronym> stays around 24%
<acronym title="High Pressure Oil Pump">HPOP</acronym> replaced last November.
New stand pipes and dummy plugs. No STC fitting.
All new orings and copper washers on injectors.
Polished spool valves with 1000grit wet sand paper.
Replaced <acronym title="Fuel Injector Control Module">FICM</acronym> harness. Connector to #5 was damaged and could of shorted out.
Fresh oil change T-6
Fuel pressure stays at 60psi under all conditions.
Cleaned <acronym title="Exhaust Back Pressure">EBP</acronym> and <acronym title="Manifold Absolute Pressure - MAP Sensor">MAP</acronym>.
<acronym title="Fuel Injector Control Module">FICM</acronym> voltage stays between 47-48 under all conditions.
battery(s) test out good.
Alternator puts out 14
Passed bubble test
Passed buzz test cold/hot


I think that covers everything. Might of missed something.

 

So at WOT, the IPR stays at 24%?

 

FICM voltage is a good tool but they can show good voltage and still be going south when they warm up.

 

Sorry, it goes to 36 at 1500psi at about 2500rpm.

 

That was my original thought but right now I can not afford just to throw parts at it. May or may not have a job in a month due to the contract I work on is ending. Would a failing FICM account for random long cranks too? It is like it has symptoms for several different issues but not enough to point to which one.

 

Take a look when cold start ficm Main ,FICM Logic , FICM Vehicle , if the main is showing 47/48 look at the other side LP , VP. also I didn't see any Turbo Values what is VGT? and do you hear the turbo spool?

 

OEM Oil cap? and don't go past the min line in Degus coolant.

 

Turbo spools, can't remember what VGT is at. I have proper boost when cold. Turbo doesn't have boost when hot due to injectors not firing properly. FICM L and V are both 13-13.5 during all scenarios. FICM main is 47-48.5 during all scenarios.

 

OEM oil cap, no oil aeration, proper level. Degas is at min line actually a little right now since I have drained it several times to remove it. Pressure is not going over 5psi. New cap.

 

When cold, WOT what is the reading VGT?
with engine warm/hot take reading in park KOEO ,low, high 2500 rpm

 

How would the VGT or the turbo affect the injectors? Turbo is working properly.

 

Sticking turbo has some weird Issues , Unisome ring, turbo veins, dirty turbo from after market filter set up, turbine hitting housing, Injects don't have anything with Turbo but Turbo Issues have a lot to do with Other running Issues, Show VGT at the above Mentioned and lets rule the Turbo Out.

 

It is 67% at idle cold or hot. I'll have to check WOT tomorrow.

 

I've had the same problem, I'm guessing you have injector problems. I had 2 that were just barely bad on the contribution test. Actually I had 1 that made no difference and 2 that we has to listen close too and sometimes they didn't do it. I fought this for a long time! It ran awesome cold and terrible hot. One other thing it never did give any codes!!

 

What is the ICP psi and IPR % @ WOT hot engine?

Josh