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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

6.0 rough/erratic idle - Need help !

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Old Oct 4, 2020 | 08:54 AM
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6.0 rough/erratic idle - Need help !

Hey guys ive hit a wall and need help figuring out what is wrong with my truck. Its a 06 f350 6.0 built heavily. (parts in 2nd paragraph) a few weeks ago I took the truck to pick up some lumber for a porch I was building on my house and the load was pretty heavy, put the truck in towing like i have time and time before when needed. Had no problems at all on the way home. Got home turned the truck off then restarted it to drop my trailer and move it out of the way and all was still good. Monday morning went to out to go to work and truck would just crank and no start. Figured it was the wiring so i moved the wiring harness around like i have before but this time is still wouldnt start. codes said crankshaft position sensor circuit open. Replaced the sensor truck started but had a terrible idle all over the place from bouncing rpms to sounds of injectors failing and sometimes it would smooth out and be normal for few mins. could move the wiring harness and truck would die, smooth out, or start erratic idle again. Replaced the wiring harness and injector harness, no change. So truck was still in tow tune so changed it back to street tune that ive ran for about a year and now it doesnt die but its erratic idle is terrible rpms drop from 700 to 350 and shows on the gauge and any scan tool monitoring. occasionally the idle will smooth out and be normal for min or two but then goes back to being erratic. Changed the ICP, IPR, FICM (board only) and nothing changed. Changed the Camshaft position sensor and truck wouldnt start at all it would make an attempt to fire and thats it then back to straight cranking. put the old camshaft sensor back in and now truck will start again but still has the same idling problem as before. if left to idle to long eventually it will throw injector contribution codes but if i clear the codes and restart it take 10 mins or more for it to throw them again. only codes im getting on regular basis is crankshaft position sensor open circuit, and manifold pressure correlation and on one of my scan tool it says no sync with cam and crank sensor. ive tried another crankshaft sensor and nothing changed. I put a camera in the crankshaft sensor whole and watched the toner ring and spun the crank but seemed normal and teeth looked okay (but first time ive ever did that so can be 100 % what i was looking at was good). All my data appears to be normal. ICP % within in ranges KOEO and while cranking, FICM holds at 48v, injector pressure builds quickly to around 1000 then starts. Ive ran out of things to that i can think of, I have worked on 6.0s for a long time including mine, fathers, friends, and others and now im just at a wall and only have two more ideas of what it could can be but they require a lot of work and a ton of money and I wanna see what other people think before i consider those two options. Please help.

Parts:
about 6 years ago motor was pulled and everything from the crank up was replaced with higher end parts (previous owner did all this) pistons and pushrods (not sure brand) I have changed out some of those parts over the years and so currently the truck has: Full Force Diesel 190/75 cc injectors (three have been rebuilt by Warren Diesel, wiring harness on the injectors go bad not the injector) , sinister diesel EGR delete, ARP Head studs, Mahle Clevite 18mm gasket set, T4 up pipes and s366 turbo, MBRP 5'' straight pipe, S&P intake, xtreme diesel intercooler and pipes, Billet pushrods, Livewire TS+ monitor/tuner, Snyder Performance custom hot tunes, Warren Diesel shelf street and tow tunes, Air Dogg II 4g fuel pump, tank sump, blue spring upgrade, Xtreme Diesel regulated fuel return Xtreme Diesel Dummy plugs, and thats all the engine parts i can think of.

 
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