I am posting this on behalf of a friend of mine, @Wes444 . Wesley please correct anything I get wrong here as I am going off memory and have slept since these events took place.

A while back Wesley had a surge condition when running down the road and at idle. I would describe this as to what @ArmyLifer recently saw from his Excursion in this thread. Wesley replaced the ICP with a Motorcraft part and the surge went away. Again, this is based on what I remember.

On Saturday the 5th of September Wesley sent me a text stating the truck was surging again... I could tell he was frustrated from the rest of his text because he is working a lot, has a new to his family home to get in order and has a large family to keep fed and happy. I asked a few of the basic and common questions and he told me that the IPR was replaced 2 years ago with a Motorcraft IPR. He does have the original IPR to swap in if he believes that is the problem.

I asked him to send me a PID data log file so I could chart it and post it here for the community to pitch ideas out.

When the ICP was plugged in, he would receive an intermittent surge condition. When the ICP was unplugged, he did not receive the surge condition, I think...

I have attached two PID Charting Tool data files with the charts completed. Their titles are named appropriately for the condition observed by Wesley.

In addition, I have taken some screen snips for those that are interested in seeing the PID Charting Tool in action, but do not have MS Excel or access to Google Docs, Open Office or another xlsx file viewer.

Surge condition chart...






No surge condition chart...

 

I have somewhat of a similar issue once in a while, more when towing heavy, cruising along at almost an idle maybe 1-3 percent throttle input to help maintain speed my truck will start bucking and surging, let off throttle it will stop. I have narrowed mine mostly to tunes having throttle input to sensitive, and am awaiting revisions to see if it helps, my 1023 daily tune does not seem to do it, but aa, jelibuilt, and sdk do.
It could also be a bad spot in the tps
I have also seen poor torque on injectors cause this.
Hopefully someone else will chime in, with more insight then I can provide

 

I just replaced my ICP sensor (again). I’ll report back tomorrow if it’s any better. No surge with ICP disconnected.

 

Take a good look at the ICP pigtail too. Give the harness a manly handshake while at idle, see if that has any effect.

Also inspect the underside of the harness at the 42 pin connector.

 

Thanks for the suggestions so far. Like sous said Motorcraft IPR and ICP 2 years ago, when it started surging this spring and unplugging fixed it I replaced the 18month old ICP from Clay with another MoCft from Clay. Still surged. Cleaned electrical connectors, still surged. Checked and wiggled harness, still surged. One day it magically decided to stop surging, was around May during the move.

Fast forward to Saturday, started up again on the highway, it felt like double or triple the expansion joints there should have been, during shifts I could detect slight rpm jumps, happened to glance at lie o meter and it was saying 32.5mpg pulled over, unplugged ICP, no more surge and eventually the mpg worked itself back to 22.5

So, I have 2 pretty new ICPs I can play whack a mole with, along with the original IPR that ended up not being the problem, darn fuel bowl heater.

I have a longer drive in the morning after I get off this nightshift to log some extra pids and try and see something

 

Just FYI, thanks to @FordTruckNoob I found that Motorcraft parts, including sensors, are covered by their 2-year warranty. Those ICP's are pretty expensive boogers, so contact Clay and you could probably return both. After replacing my ICP last night, truck ran smooth as silk on the way in to work today.

 

If the problem goes away with ICP unplugged, I’m gonna say the sensor is bad - again.

I have a friend in WA that appears to be having a problem with an ICP sensor he replaced last year. (Oil in plug and no-start)

It is disturbing that these ‘new’ OEM sensors appear to be problematic...

 

The first new Motorcraft going bad in 18 months sucked, but a second one going bad in 3 months? Gimme a break, horrid QC. Almost makes me wanna try an Autozoo one for $4 and swap them out at the same frequency rather than deal with the dice and warranty on $180 ones.

Got some good long logs of the surge that turned to nearly bucking on the drive today

 

@Wes444 sent me an email this morning with another FORScan data log and a comment, which I have pasted below.

Quote:

Originally Posted by Wes444 via email

Lot of surging and nearly bucking around 507-697 seconds. Everything looked good but ICP jumping all over the place

Below is the portion of the raw data log including the time stamp Wesley specifically identified.



Based on the raw data log, I suspect Wesley misidentified the time stamp of 507-697 having an issue, but I will let him expand on that further.

I have attached the new PID Charting Tool output for anyone wishing to take a look at it.

Below, I have also provided some snipping tool images from the chart. Upon immediately opening the populated chart, I saw the ICP is all over the place. I mentioned to Wesley last night via text that he needed to use the first ICP PID in FORScan, and I thought perhaps he selected the wrong ICP PID, but upon further inspection the ICP is steady in some places. So, I will post up a few snips of the chart where the ICP is out of whack a bit and let people see it for themselves and Wesley can go from there.

Notice the FUELPW is erratic as well, as you can see below.

Smooth running...



Not so smooth running...



More not so smooth running...



The FUELPW and ICP continue on like this until toward the end of the data log session, where it smooths out a bit to normal. This is viewable in the attached chart.

 

There was someone on here several months back looking for alternative sensors of quality. Maybe it was Walleye Hunter or Brokestroke or someone else, not sure what they ever came up with or who it was even.

 

That looks like an ICP sensor failure to me as well. It was not jumping out to me on the "Surge Felt" log, but clear as day in this one.

 

This seems very similar issue to what I have going on once in a while. Especially after letting off the throttle and letting it coast, or at just 1-3 percent throttle light footing it. My icp is oem and only a few months old as well, I suppose I will check that too.
Interested to see the what this turns out to be

 

I found an ‘03 van turbo with Garrett on the exhaust housing.

Easily overlooked when it’s all BROWN I guess!!