First off long time lurker, first time posting on the 6.0. I'm amazed at the help that is given here and you all have helped me without even knowing it.

I finally got a OBD2 scanner and loaded up Torque Pro on the cell as I know you all would want some numbers. Not sure I got what is needed, but here is the saga.

Truck: 2005 F250, 99K miles, new HFCM and blue spring upgrade 11/12, just changed fuel filters (Racor/OEM), just changed oil Rotella 5-40 syn with Racor oil filter, coolant filter bypass installed 10/10, stock donaldson air filter, run OptiXPD fuel treatment always.

Symptoms:
A month ago (no OBD2 readings as I didn't have it until today) started fine, ran to end of neighborhood then no throttle. Turned off, ran glow plugs started fine. Ran a mile I turned it off, then no start for 5-6 attempts then fired and idled very rough. did this several times. Turned it off, then no start multiple times then fired and ran normally the rest of the day.

2 weeks ago: towing bass boat to from Lake Mead, NV. Fuel economy dropped 2mpg (just put AT tires on and they were a tiny bit bigger (280 vs 265) then the hot rough start happened. Every time I shut it down after towing the boat back into and through Las Vegas it would fire, but run at 400rpm quickly coming back to the 800rpm mark within 10-15 seconds or so.

Today (with OBD2/Torque Pro): Very cold, 20-35 degrees fired but ran really rough/loud (until it warmed up) with a good puff of black smoke on start up here were the numbers. NOTE no DTCs read

ICP V: KOEO 0.2, KOER LI 0.8 to HI 2
ICP (checked the plug, no oil in the connector)560ish to 620ish at idle, HI 1850
FICM V: KOEO 47, KOER 43-44V when it first fired, reading a low of 42.5 then it slowly climbed to 46 to 47 as it warmed up and kind of bounced around those numbers (don't know if that bouncing around voltage is normal or not). Just went out after sitting for 3 hours and getting cold again and KOER was 45 and never climbed into 46-47 range (10 minutes of idle and short duration high idle).
EBP: KOEO 11.9
BP: KOEO 11.6
battery voltage: KOEO 11.9, for 30 seconds after start it sat around 12 then eventually bumped up to 13.6. this was pretty consistant during every start. Is there a good draw on the alternator during/immediately post start?? I haven't had a chance to load test the batteries, they were replaced Jan 2013, Interstates.
EGR%: no reading from the sensor. I cleaned it after the first rough start incident month ago and it was carb'd up, but not sticky/wet. I'm pretty sure I should have seen a cycle on the EGR during todays start up (gauge had nothing for high/low values)

I'll start with the batteries and load testing tomorrow. Thoughts or other data/numbers diagnostics I need to do?? FICM?? or could bad batteries cause that issue? Others info needed??

As always the members here amaze me and I look forward to your guidance.

Bob Lechel

 

There is an enormous amp load on initial start, glow plugs alone take 10-12 amps each for up to 120 seconds not counting the other 50 or so amps to run everything else so the voltage drop at initial start is normal, the FICM voltage being below 45 is not, you need to send your FICM in to www.FICMrepair.com for some lovin from Ed. He has a hot swap program where he will send you a repaired FICM out then you send yours back when you swap them out.

 

glow plugs run for a couple minutes, battery voltage looks normal. The FICM at that low voltage is not good. Anything under 45V, Ford say's is bad. Time for a new one, send it to FICMrepair.com and Ed will fix it up.

Probably why your having rough starts, voltage goes up after it warms up.

 

Thank you guys for the quick response. I was afraid of that. Looks like I know what I'm doing next weekend.

Any thoughts on the EGR not cycling today. Do they go bad???

 

Mine is gone with the delete the previous owner did. You can clean them and if it's a gunked up, I would.

 

I cleaned it 3 weeks ago when the first rough start/no start stuff started happening Carb'd up but not wet/sticky.

Just curious that the EGR% should have read something today... Sensor was showing "green" on the Torque Pro app.

Thanks again for your help