Excursion with hard start problems

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Jul 26, 2021 | 01:54 PM

Chad Ben

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Excursion with hard start problems

Please help! I’ve got an 04 Excursion 6.0 that’s been bulletproofed. I just bought it back in April because it fits all of my kids. When I first bought it it was running amazing. Last month it started doing a hard start, it would take three or four long cranks to get it to turn over (only when it had been sitting for a while). The truck has the FASS fuel system, and I replaced the fuel filters thinking that was the problem, sadly it was not. The pump is running and functioning perfectly. I replaced the starter, still hard start. I’ve since taken it to a diesel mechanic shop, and things went down the toilet from there. $2k later it’s now running worse. They first replaced the ICP sensor, that didn’t help and now it has a hard start even when it’s warm. Then they did a pressure test to the high pressure oil system and found a few internal leaks. They fixed those but then I lost 50% of my power and still a hard start. Then they replaced the high oil pressure module, that made everything worse! The hard start is worse, and now when I’m driving on the highway it randomly sputters really hard and keeps dying. I let it sit for 11 hours and drove it again. Still a hard start but ran great for about 20 minutes then started sputtering again but not as bad as before. I love this truck but I need it running since it’s a daily driver. Any help will be much appreciated!

Jul 26, 2021 | 03:28 PM

EXSwap

Fleet Mechanic

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Welcome to FTE!

Sorry to hear about your woes with the 6.0. I'd actually head over to the 6.0 forum here and check out the tech folder. Lots of common problems with solutions there and do some digging around there for your symptoms.

Mods may move this to the 6.0 forum to help get you some traction over there. Some really smart folks there that can help out.

Do you have a way to monitor parameters both while cranking and while running? Also, what was included in the "bulletproofing"? Lot's of folks say that and there's just as many way people say they've done it.

https://www.ford-trucks.com/forums/forum107/

Jul 26, 2021 | 04:30 PM

Chad Ben

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I will do that thanks. As far as I know it’s had the full bulletproof, to include fuel system egr studded heads etc.

Jul 26, 2021 | 07:11 PM

MasterX

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From: Arizona

I would recommend finding a shop familiar with the bulletproofing process on 6.NO Engines and have them check it out, they would be more likely to find the issue i think as most other shops would be expecting a stock engine and likely be confused with the differences in parts and possibly readings they get from a bulletproofed(Upgraded) system.

Aug 1, 2021 | 12:52 PM

Chad Ben

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So I was able to pull the codes, and it’s reading low injector pressure and cam sensor. Like I said before the ICP has been replaced as well as the IPR (as you guys pointed out.) I’m at a loss with this truck. Over the weekend it drove fine, but today on my way to work it was sputtering worse than it ever has and died 3 times on the highway.