Ok, Fuel Pressure is at 50 psi at 2500 RPM at the fuel regulator test port with a mechanical tester.

The fuel pump turns on with the key and after about 5 seconds you here a gurgle, but the pump continues to run.

On driving under normal conditions around 40 MPH I can hear the fuel pump "surge" in and out. That is about 1200 RPM.

So what would be our next step?

I talked to a local recommended mechanic and he said it sounded like a sticky IPR Valve...

I am at a loss.

 

For what it's worth i've been having some similar issues with my 04 f350. I've done some research and believe my issue is my FICM. I found a great informational video on youtube that explains how to test your FICM and make sure it's working properly. In the event it isn't working properly there's a thread in the Tech section that has an awsome, detailed instruction as to how you can fix your FICM yourself. I only mention this because it was pretty easy to check and it helps eliminate possible problems.

 

If you're not testing the fuel pressure under a load it's not really a true test. Just running the RPM's up to 2500 with the truck sitting won't really tell if you have a pump issue, however I do think your fuel pressure is marginal. I am puzzled how you can hear the fuel pump surge in and out and if that's what you're really hearing. The factory fuel pump is almost silent (at least to me). I can barely hear one running without the engine started, much less driving--LOL.

It's very possible you could have an ICP/IPR problem but you'd really need something to monitor those. More likely the ICP than the IPR. They are notorious for leaking and failing on the 03 motors but I'm not one to just throw parts at something without diagnosis and it usually causes a full time stutter/shudder.

No smoke from the exhaust with a heavy diesel smell puzzles me. Usually with overfueling you would get black smoke. Have you checked the airfilter for an obstrution (rats, mice, birds, chipmunks, etc)? Do you know what brand of air and fuel filters are installed? Have you code scanned this truck???

 

Beginning to think its the fuel filters still.
It ran fine one day after the filter change that the dealer did Saturday.
The Dealer (Used Car Dealer not a factory dealer) said he got the Filters from Autozone which do not carry Motorcraft or IH. (Only O'Reily's carries the Motorcraft Filters here in my area I found out)
The "gurgle" I hear when I turn the key and 5 sec after the fuel pump starts makes me think that is it, because it is pushing the air out.
Also going to replace the flat gasket under the EGR Valve, as it was missing when I cleaned it.
The fuel smell is not as bad now. I am beginning to suspect that when the guy changed the lower filter, he got fuel all over the frame rail, and just needs to finish evaporating. Also could be a cut O-ring and sucking air and leaking a little (Thanks Bob for that tip)
Air Filter is clear, I had it off when I pulled the EGR Valve.
The Shutter and Stutter was the reason I had them change the fuel filter in the first place.
Should the ICP Sensor throw a code if faulty?
Also I remember reading about a recall on a connector for the ICP I think, not sure now that I have read so much and talked to so many people.
This forum thread is the only thing keeping me straight as I have documentation of what I am doing.
As for hearing the fuel pump while it is running is more of a feel and hear.
I can only hear it with the windows up and I really have to concentrate on it.
As for having it scanned. The truck was well maintained until 2008, when it had a new transmission installed at the Ford Dealership in Atlanta. Then after that only 12k miles were put on in in 3 years, and had one service at the dealer in late 2009, and again in October of 2010, when the Georgia Dealer bought it.

 

Here is the Recall I found. I am sure you are all aware of it. When I enter my VIN in Ford's Recall Database, I get -No recalls.
My truck is a 2004, but has a 2003 engine.

Model Year(s): 2004, 2005
Mfr's Report Date: July 22, 2005

NHTSA CAMPAIGN ID Number: 05V270000
NHTSA Action Number: EA05003

Component: ELECTRICAL SYSTEM:WIRING
Potential Number of Units Affected: 180104
Summary: CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Consequence: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Notes: FORD RECALL NO. 05S34.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

 

That recall does not affect 2004's with a 2003 Engine.... Just talked to Ford Customer Care.

 

Ok, just goes to show do not rely on cheap computer scanners.
Had my truck scanned at the local 4x4 / Diesel Performance Shop.

Bad Egr Valve, fault on the 1, 3, 5 and 7 glow plugs (probably a connector since it was all on one side), and a fault on the Exhaust Back Pressure Sensor (hopefully just a carbon blockage).

Fuel Pressure was also tested correctly this time and was told it was 67 PSI.

Have EGR Valve in hand (Doing a Delete in a month or two) going to clean the Exhaust Sensor, and check out the glow plug connectors.

Cleaning the EGR must have just completed the final failure of it.

 

If you are blowing out diesel smelling smoke you do not have a fuel problem!!!! Still you should get a fuel pressure guage to know where you stand. Only a guess from this side but, I believe you have a turbo vane sticking problem. NOT a turbo seal. If your turbo seal were to be leaking you would notice your oil level lowering.

 

Color me fixed.

EGR Valve had stuck open partially. Carbon Build up in the tube to the Exhaust Back Pressure Sensor, and the glow plugs, I dont know...
The connector seemed fine. I pushed it together just to make sure it is snug.
Gonna have it the codes cleared and rescanned tomorrow.

Thanks for the Help guys.

Still doing the EGR Delete later and the fuel regulator upgrade, and in cab fuel pressure gauge.

 

Did you ever get the truck fixed?

My brother has an 04 F250 6.0l, which is suffering from similar symptoms. He ran the truck low on fuel last week and ever since its been stuttering and lost power.

It will run fine until about 2500 rpms and then lose power. Seems like its running out of fuel. He changed the fuel filters today, didn't prime it right so it was hard to start at first. Got it running, it ran fine back to normal. Parked it then it started acting up again just as it was before. He doesn't live close to me, but I told him first thing to do is check fuel pressure. It seems like the logical starting point and then we can troubleshoot from there.

Also on long hills it seems to lose power, which makes me think its the pump.

 

Yes. The "Fuel" issue was a bad gasket on my EGR Valve. Exhaust was bypassing the valve and blowing into the engine compartment mimicing an out of fuel problem. If it is happening you will see soot marks coming out around the EGR Valve where the 2 bolts hold it to the manifold.
Start the truck and "rev" it up a few times. Then stand by the doors of the truck and see if you smell a heavy diesel or exhaust smell.

I had other issues as well. I bought mine used with 80k miles on it thinking I had a nice low mileage truck.
Here is what I ended up doing to it...
1. Replaced EGR Valve and Gasket
2. Replaced IPC Valve (Did while Transmission was out)
3. Rebuilt Transmission plus torque converter (Monster Box Rebuild)
4. Cleaned Exhaust Back Pressure Switch
5. Rebuilt Fuel Pressure Regulator with Blue Spring Kit
6. Replaced #1,3,5 and 7 Fuel Injectors (1 and 7 were Bad, but replace the whole bank because I already had the top of the head part) Also was the cause of my Bucking Problem
7. Replaced Rear Differential Seal at Drive Shaft
8. Replaced all Tie Rods (Broke one by just backing up)
9. Replaced Idler Pulling to fix A/C squeal
10. FICM Reprogrammed
11. Computer Reflash (Ford Factory Update)

Went from 11.8 MPG to 17.5 MPG after all the repairs. Runs like a scalded dog now.

When I pulled the Service Records from the place where it was serviced last before I bought it, they had the turbo inlets replaced, a fuel system flush (Whatever that is), a transmission replacement at 53k, and 2 EGR Cooler Replacements.

I would recommend him have it scanned. I was surprised by all the codes mine was popping, and some of my codes masked others until I fixed those issues. I have a friend who has one and we were able to track down all the issues. My local Ford Dealership does a Scan for $70. Do not do a "Autozone/Advance Auto/OReillys/Etc" Scan. Those little check engine light scanners will not give you the codes.

My plans are to do an EGR Delete in October as I believe I am getting ready to have another failure as I have White smoke when it starts now. And I am going to bag the read end with the Firestone R4Tech Bag/Spring System.

 

Thanks, I will pass on the info.

 

wait isn't your truck a 04 with the 03 build motor in it? If it is it should have the round egr cooler and they don't fail. However it could be oil cooler they are replacing. My truck has a 03 motor in it as well. I love it and it runs awesome and i'm getting 17.5-22mpg.