Ok... I am stumped (as well as numerous mechanic shops).
When I am on the highway, my 2005 Excursion (6.0) will hesitate/sputter/buck intermittently, usually between 70-80mph/ 1800-2200 RPM, but especially triggered by hills and inclines. Each sputtering episode usually lasts about 5-10 seconds and then will go away for minutes at a time. Does not sputter upon take off or initial acceleration. There is no smoke of any kind. Just got it out of the shop where the mechanic replaced ALL 8 injectors and the fuel pump, as well as flushed the fuel lines, and new fuel filters, and oil change (2 injectors were bad, but there was metal in the fuel filters, so to be safe I replaced all of them - ALL OEM PARTS for everything, including filters).
The week before, I had the IPR valve replaced. Also, recently had the back pressure sensor replaced and the EGR was deleted - and turbo cleaned when the EGR was deleted last month.
I also tried unplugging the ICP sensor to make sure that wasn't the issue.
Dropped $6k into this thing in the past month and about to lose my mind (and wallet). All research points to either clogged EGR or bad fuel injectors, but both have been addressed, so I am not sure where to look next. No current codes showing up. No signs of leaking oil.
Plan on doing the Blue Spring upgrade this weekend to increase PSI to injectors, but I am guessing that won't fix this problem.
ANY IDEAS? Could really use some help right now - THANKS!

 

What are you monitoring live data with?

 

For starters, the mechanic did not fix the issue so it theoretically it should go back until it's fixed.
The blue spring will certainly not hurt anything, not saying it's the issue but you might see some difference......hard to say.
Also, as KD mentioned, how are you reading things live?
Almost sounds like the fuel is getting aerated when demand is moderate to low.
How bad was the upper fuel filter for shavings?

 

Thanks for your response! I appreciate all the help I can get on this.
I agree and would take it back. But the part of the story I left out was that the injectors/fuel pump/filters were replaced in Phoenix while on vacation (by a diesel shop with about 20 all 5 star reviews). I believe he would continue to search if I still had the truck there. Now we are back home in Texas and starting over. I have yet to find a shop I really trust and I will be trying another one today.
I never saw the metal in the filters but he said there "was a lot of debris" in there.
I was wondering if air was still getting in the fuel line some how. The problem is so interment. A few hills no problem, then all of the sudden hesitation and bucking on the next hill. Then back to normal again.
Also, I will be checking the live monitoring shortly. What am I looking for? Psi?
Thanks again!

 

If you do not have a way to see the "LIVE DATA" - via a ScanGaugeII or like instrument, it'll be difficult for anyone here to help you. Do you know if anyone checked the voltage on the FICM? Look here: https://www.ford-trucks.com/forums/8...procedure.html

 

Great thread! Thanks for the info. I will definitely look into that! I'll let you know if/when it's ever correctly diagnosed.

 

Before you get too carried away I would put the blue fuel pressure spring in since you don't already have it.

 

I believe the 2005 excursions kept the 04 motor. Check to see if you have a throttle plate and if you do remove it. This might solve your problems.

 

Yes, I had heard 2005s were the left overs from 04. I will check that. Thanks!
In the shop right now... Waiting to hear this week's diagnosis!

 

Unplug the ebp and test drive it. You will set a code for ebp.
If it goes away I can make a guess at what and where the issue is.

 

Good suggestion! As soon as I get my car back I will try it assuming the problem isnt solved by then. Thanks!

 

What is your guess, cheezit? There's another post with this same issue (and myself) that have had surging fixed by unplugging an EBP

 

Most Ford dealerships have a diesel shop, there tech streams live data streaming is made to diagnosis your truck. I'm not saying get work done but they should be able to point you in right direction.

 

Turned out in the end to be a bad pig tail wire connector on the turbo! So after spending over $4,000, but turned out to be a $5 part.

 

Good to hear that you solved the mystery, however not good that it cost so much. How and who finally found the bad connector? It might help someone in the future with a similar problem.

Glad you're back on the road.