Hey fellas -

I have been reading some of the great tech information at the top of the forum, but much of the reading has given me more questions. I have an 06 6.0L 350 that has just recently started to have a few issues, and I was hoping for some advice on how to move forward.

As of lately, when I go to fire up the truck, the starter turns much "longer" than it used to before firing, and when it does fire, the RPMs jump up, fall and jump again before settling to the normal running RPM. I swear I can smell fuel through my vents and the gas mileage is showing less than 10mpg (used to be 14-15). But I see no visible fuel leaks. I am confident that it's a fuel issue, probably injectors. Once running the truck runs just like normal, no skips, no lack of power, just normal.

I have an extended power-train warranty and was thinking of taking it to the dealership, but honestly I've been down this road with other vehicles and dealers are not always the best solution. I read in the tech forum about making sure the "software" is up to date on these models - is the dealer the guys who have that software? I am debating taking it in or going to a couple of good local diesel mechanics around my area.

I appreciate any advice on what to do, and my apologies if I didn't search enough before posting. My hours at work don't allow me to comb the internet for solutions, and most of this tech is over my head anyhow.

 

Hello General!
There are options for testing and software updates from private shops but if the warranty is from Ford I would recommend a dealership. It relatively common for the fuel pressure regulator to leak. There is an updated spring available (and recommended by Ford/International) that will raise the fuel pressure a bit and provide some additional cushioning to the internal parts of the injectors. You may be correct about the injectors being the issue if they have operated for an extended time with low pressure. The kit comes with new seals that will address the leak issue.
The latest software is the only thing available from the dealer and it has proven to be a mixed bag of results. Many reports here (and other sites) of lower fuel mileage and reduced power.
I would suggest local dealer install "blue spring" fuel pressure regulator update, inspect for other possible fuel leaks, perform injector diagnostics, and NOT update the software.
Welcome to FTE!

 

Sounds like a plan - thanks for the help, and the welcome!

 

My guess would be injectors... I had a similar issue with my truck (varying RPM on cold start and significant mileage drop) which was solved by replacing three injectors which turned out to be bad. I'd echo the suggestion to go to the Ford dealership if that's where your warranty is. Hopefully your dealership has a mechanic who knows these trucks, though, because some of the Ford mechs don't know diesels that well. A bunch of the guys here are really knowledgeable so they can confirm and verify anything your dealer tells you.

 

I would get a set of gauges something like the Edge Insight CTS to check the health of the motor, plug and play. You may also have a bad FICM that may be covered under warranty any thing under 45v going bad. I would not have them do a flash most of the time your mpg will drop.
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Just a bit of an update for those who have been helping. The dealership found that the fuel/water sep. sensor was bad - the light would always come on after draining multiple times and I just figured we have really crappy fuel here or something. However it's stopped coming on. The fuel smell was a bad O-ring somewhere in the fuel line set (as I said I'm definitely no mechanic so I'm not 100% sure of the particulars), which they fixed. I replaced a battery myself as well - Ford told me I needed to, and I verified cranking amps at the local Advance before doing so.

BUT, I ended up putting in back in the shop yesterday. I live in NC, and the mornings are beginning to get colder, but I would not say FREEZING or anything beyond normal winter-ish weather. The truck took almost 10 seconds of turning over before it fired.

NEW QUESTION: In the colder mornings, when I fire up the truck, it runs like Pure-T-Dog-*****. It sounds like parts are banging around everywhere inside, or like no oil is going into the head and parts are slamming each other. Once it warms up for about 10 minutes, it's fine. Drives fine - no worries at all. Even my dad was like WTF when he heard it. This is only an 06 model. For you guys around that age, is this normal? Should it run so rough when you fire it up? I wish I could give you audio on it.

 

Sounds like you need to use a 5w40 Syn oil something like Rottella T6 you can get it from Walmart and Ford filters also from Walmart FL 2016. Also sound like your FICM may be going bad need to check
Testing the FICM
http://ficmrepair.com/
My choice if repairs are needed.
If you have a cold weather plug, plug it in for about 3hrs then see how it runs at start up.
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Thanks Dieselpop - I will definitely test this. Thanks for the good info!

Davbeisner - you are correct as well. I spoke with the service tech this morning who said I have 3 bad injectors. They are working on providing the fix under warranty.

However, my first question when I ride back up there will be, as nicley as possible, "why the hell wasnt this found last week????". My own common sense would tell me, if there is low fuel pressure to start with, check and ensure the system is operation, which would include injectors in my opinion. Maybe I'm wrong - I can't say I'm disappointed - I've always avoided having the dealerships work on them for a reason..

 

One other suggestion. You should always change the batteries in pairs. The older one will short live the new one and be a drag on the system.

 

Maybe so ... I had them both tested. One tested at 842 cranking amps (850 rated), so I did not replace that one. The other was down 150 so I swapped it.

 

Follow Up:

Thanks again for your help guys. I'll post a quick rundown of what they fixed/replaced on my truck - maybe it will help some of you in the future who may have the same issues.

Trip 1 to dealership (Not Covered Under Powertrain Warranty): They replaced the fuel/water separator sensor which had gone bad. The fuel smell I had was due to a a bad o-ring for the fuel filter at the fuel/water separator. The "Water in Fuel" light doesnt keep coming on and the fuel smell is now gone. +/- $ 530 bucks.

The 2nd trip to the dealership was because they didnt keep the truck long enough to do a true cold start. Once they did, they found a few more issues, which as as follows:

Trip 2 to dealership (100% COVERED UNDER POWERTRAIN WARRANTY): They replaced the valve cover gaskets. They also replaced dummy plugs and injectors 2, 4 and 8. They tested air in the line and ended up putting on a STC replacement kit. +/- $ 2,300 bucks covered under warranty.

To date, the truck starts great in the colder mornings, and runs better in general. The gas mileage has increased to where it was prior to having the issues. I never thought I'd say this, but I'm happy with the dealerships work and customer service throughout the process. I'm very surprised it was something actually covered under warranty and not the typical "Welllll, the warranty doesnt cover this part" story.

I have come out on the better end of the deal here - the warranty was originally around $ 1,500 bucks so I feel I've got my money out of it.

 

Glad you got it squared away! Nice to hear of a good experience from a dealership. Too often it's complaints. You might want to post up the Dealerships name in case someone in your area might want to use them.

 

Hilbish Ford in Kannapolis NC. Jason was the customer service rep I dealt with - very good guy, very knowledgeable and very helpful for me. +1 for those guys.

 

now, give yourself a +1, and go to autozone and get a scanguage II
and start monitoring your engine... there is a tech folder up there ^^^
with a ton of information.

this is very important.

coolant, alternator and battery voltage, and oil changes are the
three big sinkholes on this engine. if not maintained correctly,
they can cause cascading problems above the $5k repair bill level.