I have an early 2004 (mfg 9/2003) Excursion with a 2003 model 6.0 Powerstroke. All I have done to it is put a cleanable air filter. Problems started 4 months ago. The truck died on a trip. Out of town shop replaced the HCFM. It worked fine till I got halfway home and started running rough, mileage dropped, etc. I didn't drive it much for the next couple months and started saving for repairs. Then it died on me again. Ficm voltage was low so I changed it. Same problem. Rough idle, very low power till it warms up, shaking from 45-65 in overdrive, and no check engine light. Brought it to a local shop. #5 injector was bad and replaced. They also changed the IPR and an o-ring on the HPOP. No change. Shop tells me there is still a miss in #5 cylinder and it has low compression. They 'think' the cylinder is galled and the rings aren't sealing enough to make compression. They want to overhaul the engine for 5 grand. Wouldn't that cause smoke out of the exhaust pipe? There is no smoke. The truck is sitting in the yard and I'm out of ideas. I am thinking a fuel pressure or valve issue with an additional transmission issue. I have heard many bad things about this shop since I brought my truck and don't trust them.
Any help would be appreciated.
First post. Sorry so long.

 

Perform a manual compression test on #5.
Disconnect icp sensor and road test, if its better replace the icp and connector

 

Just had an 05 with a plugged catalytic convertor drive the owner crazy, cut it off and runs like a champ. For your problem you need something to monitor the engine and not throw parts at it. You could have picked up bad fuel and they changed the HFCM for no reason...just throwing my thoughts out there.


Fresh start: Give us more info on your ride and what you have to diagnose with, go from there.

 

bad fuel.... would you consider jet a and extra fuel lube additives bad fuel? it was free and works fine in my other truck with a 7.3

 

i will do a manual compression test and road test with icp sensor disconnected this weekend.
what should i look for with running it with the icp sensor disconnected?

 

i dont have any diagnostic equipment to give any more info. with the 7.3 i can feel or hear what was wrong. with the 6.0 everything sounds/feels the same when it breaks. im going to have to get something to monitor it and give me numbers cause i'm just guessing without it.

 

Good info on different monitors in this thread that Rusty started.

https://www.ford-trucks.com/forums/1...eral-info.html

 

thanks for the link. a monitor purchase is on top of my to do list this weekend

 

Jet A has no lubricity and replacing 6.0L injectors is not worth the savings. What you got away with in the past using Jet A in your 7.3 could have cost you.

 

Agreed, the 6.0 is built to tighter tolerances than the 7.3 and things you got away with on a 7.3, you can't on a 6.0.

If if need you picked up some bad fuel, head to Autozone and pick up some Stanadyne Blue label.

Performance Formula « Stanadyne Additives

Also, where are you located?