So...

The truck finally died on me today. I let it run 8-10 minutes before I left work this evening, and about 1 minute in to my 5 minute drive home, it started bucking like it does on occasion, but this time it actually died. Fortunately, I was able to coast off of the road.

I tried restarting it a couple times, and it would fire right up and then die instantly. I let it sit for 2-3 minutes while I made a few calls, then tried to film the issue, and what do you know, it fired right up like normal, and drove home normally.

CEL never came on, gauges all look fine. 1/2 tank of fuel.

Unfortunately I do not have access to a scanner such as AE, and I don't know anyone offhand locally who does. I'm going to check the UVCH this weekend to eliminate it as a possibility, and it's a quick and easy check.

I remember reading somewhere about a guy having a similar issue, but can't find the thread anymore.

Anybody have any other thoughts? I know AE would provide lots of useful insight, but I just don't have the means to get it. ICP is new, CPS seems to be A-OK because the tach moves while cranking, and I'll know about the UVCH in a few days.

 

My 96 C&C started dieing at random times. Sometimes it would start right back up, other times it had to sit 5 minutes or so, but it would set the check engine light. When the codes were pulled there was a "pressure above or below the required amount". Turned out the tin nut on the IPR was missing. Replaced the IPR with a used one, and all was good for a while, then it started all over again. That time the IPR was replaced with a new one, and I have had no problems since.

 

Thanks for your input.

I received a "used, known good" Motorcraft IPR from the seller when I bought the truck. I haven't installed it yet because I want to know more about the viability of rebuilding them. I'd rather not spend a couple hundred on a new one, if this used one can be rebuilt. Do you know anything about that?

Well, update time already. I figured since it did in fact start up and get me home after that little incident, I could fire it up and run to the store.

It started normally, idled about 20 seconds, and died. Started again, normally, idled about ten seconds, then died. After that, it would do the same thing. Start for just a fraction of a second, then die. Repeatedly.

 

You can't really rebuild them. You can take em apart and clean them. I've seen a couple that had poor service intervals get a thick oil/sludge build up causing it to stick

 

The pin in the top of the pic isn't part of the IPR

 

There's a website i found that sells rebuild kits that consist of three o-rings, the spacer, and the tin nut. It seems to me that the thing either gets a sludge buildup like you said, or the o-rings fail. Both of those can be fixed, I don't see the point in spending $100-300 on a new IPR when a good cleaning and a $10 set of o-rings should revitalize it.

 

The IPR is a wearable part the parts move back and forth putting wear on the inside which overtime causes it to stick.

 

Try running the truck with the ICP unplugged

 

ICP isn't the issue, I just dealt with that a few weeks back. That's about the only thing I can confidently say is not the problem.

 

Have you changed the cps

 

IPR Injection Pressure Regulator 96-03 7.3L Ford Powerstroke IF A 96 OR NEWER IPR

IPR Complete Re-Seal kit for Ford 94-03 7.3L Powerstroke RESEAL

ORINGS ONLY IPR O-ring Repair Kit for Ford 7.3L (94-03)

take it apart and clean it up. I would not write off the ICP sensor until you get a data reader on there...

 

CPS has not been changed. I ordered one, but i think it got lost in the mail. Gotta check with the post office this weekend. The tach jumps while cranking though, so i thought that showed the CPS was good.

 

CPS has not been changed. I ordered one, but i think it got lost in the mail. Gotta check with the post office this weekend. The tach jumps while cranking though, so i thought that showed the CPS was good.

 

Have you checked the wiring on the pigtail going to the back of the IPR? If that wiring gets chaffed in any way, it can do exactly what you are describing. The checks you have been told to do are 5 min visuals you can do on the side of the road. I would suggest doing so before trying to go anywhere again. You may find your issue is very easily fixed.

 

I haven't checked it, I'll add it to my list though. Thanks for the tip. I've got the suburban today until the truck is back up and running.

If that pigtail gets chafed, what is the fix?