I have a 2003 Excursion with the 6.0 with 160K miles on it. When driving down the road it will sputter/stumble (almost like you shut the key off for a milisecond) for a split second and then run normal. When this happens it feels like a gas motor that is missfiring. It may do this one time and run great for months or it may do this for 50 miles. There doesn't seem to be any reason to when it happens or how long it lasts for. It can go months without ever happening and then sometimes it happens all the time.

I have had it to the dealer and they can't find anything. Here is what I have done

-Many oil changes as I have been chasing this problem for a few years
-Fuel filter changes and drained
-FICM removed and sent of to be repaired
-EGR valve cleaned with new o rings and gasket (never replaced with a new one though)
-Turbo pulled off and sent out for rebuild where it got cleaned, new seals, bearings, balanced etc.... They were suppose to test the VGT valve but I am not 100% sure what the test consisted of
-5 injectors and the fuel pump were replaced a few years ago on a seperate issue but when I took it in for the sputtering issue the dealer said all injectors were fine.

So does anyone have any ideas? When it sputters my boost gauge doesn't seem to move.

 

subing....Ours started doing the sputtering this weekend but only when sitting still. Hope someone can shed some ideas.

 

When was the EGR cleaned? may need to pull again. also the MAP connection to Intake pull and use carb cleaner the little hole on the intake gets clogged aswell you can run a peice of weed eater line thru the hose, if all this and the truck still runs bad EBP senser . also do you have a gauge to read live data ( scangauge or dash boss of the like this will help ) to look at some sensers, batteries ,ficm,alt, Map,Ebp,Icp,Ipr. if so post like this
koeo(key on engine off)
LOW ( in park idioling)
HIGH ( 2500 rpm )
theresmore but lets see what the guys think first OH and ware SAFETY GLASSES that carb cleaner burns like hell

 

Just cleaned EGR. The MAP sensor is the one in the intake tube right?

 

Yes the fitting and in the intake lil hole lot of build up, let us know how it looks and runs

 

I forgot to mention , sorry , Dont take the hose off the fitting ,just off the MAP senser it selve and Intake, run weed eater line thru with a few sprays of carb cleanner , ware your safety glasses

 

Being his truck is a 03 then the EBP SENSOR probably doesn't function anymore . There was a recall that disabled them .

 

I'll have to go look and see if I can find what you are talking about. The sensor I am talking about is just behind the aircleaner with 2 safety torx screws that hold it in. It is a square shape with an electrical plug. No hose.

 

OK I got it. I was confused when you said it was in the intake. Mine is on the firewall. I took it off and spayed it. It wasn't clogged or anything but then my EGR valve has always been pretty clean too. Anyway I checked the hole and also shot some air through the hose to make sure it wasn't clogged.

When I first turned truck on I got a code P0237 Turbo Boost Sensor A circuit low. I cleared it and it came back. I had to clear it a few times but it seems to be gone now. At first I was afraid that I messed it up by poking around in that hole.

Anyway it is cleaned. Could the EGR valve be bad? When I pulled it out it is free and you can push it up with your finger and like I said it never has a lot of carbon build up. I hate to spend $250 on one if it isn't the issue.

 

OK, you have an 03 I would think the MAP senser is on a flat bracket bolted on the top of the heater core passengers side a 14'' x 3/8 hose could be 1/4 runs behind dip stick into top of Intake, Thanks wulfman didnt know about the recall ebp senser.

 

Well I t
Must have cleaned the MAP sensor to well. I advise a lot of caution sticking anything down in the hole. I must have punctured the diaphragm. So anyway now it has a new MAP sensor on it. 200 miles and no sputter. My fingers are crossed.

 

I never spray or cleaned the map senser it selve just the fitting that screws into the Intake and hose, so at 200 MI ? hows it running you may have to keep cleaning when the soot build up that and the EGR gets pretty messed up.

 

Hows the truck , one more senser to look at in the Intake behind the fuel bowl will be the IAT2 senser , its part of the soot build up from the Intake