I have a 2003 6.0 that I just did head gaskets on, drove the truck 30 miles and started to misfire. limped it to the shop and once shut off, it would never restart. I was getting no injector buzz when the key was turned on. removed all injectors and found all of the spool valve were stuck. Disassembled injectors and freed up the spool valve and reinstalled. Performed an injector buzz test several times and all injectors passed. Fired up engine and ran for about 10 minutes and started to miss again. Like before, shut the truck off and no injector buzz again. All the spool valves are stuck again. Engine has brand new 10w-30 diesel oil in it, FICM voltage hold 48 volts and both 12 volt power to FICM holds voltage. Ive been reading about injector "stiction" issues but not sure if this is whats going on or something else. Kind of wierd. I'm a diesel mechanic for about 5 years now and worked on tons of 6.0s. This is the first one ive had with this issue.

 

welcome

hows yur fuel pressure, ficm syncs, fuel pump and fuel filters?

Also, any potential oil leaks from the head gasket replacement?

 

Haven't checked fuel pressure yet, FICM sync is good, fuel filters are new. Builds plenty of icp pressure.

 

Do you maybe have a bad logic board on your FICM? That would cause these symptoms.

 

Thanks for the replys, Would a bad logic board affect the voltage readings out of the FICM?

 

The FICM is what actuates the spool valve solenoids.

 

I understand that but was just clearing up things on my part. I have steady 48 volts and both 12 volts signals are steady. FICM sync is good as well. My question is if the logic board is bad, are any of these readings affected?

 

MPower, LPower, and VPower can be fine and you can still have a failure in the logic board.

 

Ok, thanks for the replys. I'm going to swap out the FICM

 

IMO it would be better to send to FICMrepair.com for them to test - unless you have a known good one to try in the truck.

 

The fact it ran for 10 minutes makes me wonder if this couldn't just be a faulty wire connection, bent pin at the connectors or similar issue. Since you just did head gaskets, maybe something got damaged during assembly/disassembly?

If you don't have it, link to Technician FICM Guide for the 6.0L Power Stroke Engine

 

Throwing parts at it is expensive. I’d be sure of the issue and go from there. Call FICMRepair and talk to Ed.

 

I've checked all of the wiring and even swapped out the injector harness with a known good part. I have access to a good 03 FICM that im going to try before i repair or replace this one. It will be my weekend project. Thanks for the info, I will contact Ed as well.

 

So I swapped out the FICM with another off a running truck, Did The same thing ran for about 20 minutes then started to misfire. Shut it off and only had maybe 1 or 2 injectors buzzing. Definitely have a stiction issue going on. Maybe oil contamination? Let the vehicle sit for a couple days and the spool valves freed up by themselves. Maybe changing oil again and adding some of this stiction additive i'm seeing ?

 

I’d open them up and clean the spool valves in an ultrasonic cleaner and acetone and also clean out the spool valve bores with a small industrial grade pipe cleaner and acetone then fill the tops of the injectors and oil rail with oil before putting them all back together. I’m not a fan of snake oil (stiction additive) but to each his own.