This morning, I noticed the truck was very hard to start. Took about 5-6 seconds of rolling to get it to fire. Once it fired, it ran fine all the way to school. It sat and got cold until the afternoon when I left.

As I was starting it up to pull out of the parking lot, it took FOREVER to get it started. Rolled and rolled until it finally decided to start up. I was getting a little concerned by this point as the new motor doesn't even have 1000 miles on it. I drove it home. When I got there, I checked the oil level, wiring harness, all the usual culprits and found nothing. I let the truck cool for a few hours (as it never really gets more than warm from school and back).
As I left for dinner tonight, I got in the truck and tried to start it again. Rolled and rolled and rolled and finally fired. Check engine light was on.
As I sat there looking at the light, I occasionally glanced at the motor in the corner of the garage just thinking, and KNOWING, I was going to have to spend my weekend changing it. I was nearly half sick at my stomach.

I turned the truck off and scanned the codes with my SCMT. I about filled my pants when it showed codes 1 through 11. Seeing that I had eleven trouble codes, I wanted to die at this point. I flipped in the book open to check the code numbers, and all 11 turned out to be glow plug circuit errors.

P0670-Glow Plug Ctrl. Circuit Error
P0671 Through P0678-Glow Plug #1-#8 Circuit Error
P0683-Glow Plug Ctrl. Mod to PCM Comm Circuit
P0684-Glow Plug Ctrl. Mod to PCM Comm Circuit Range/Perf

After seeing that they were all glow plug errors I calmed down realizing nothing was catastrophic. After pondering for a few minutes, I came into the house and searched through FMCDealer and found the shop manuals for the 6.0 Engine. I printed the glow plug removal instructions and proceded outside to pull one out. After pondering again, I came to the conclusion that 8 glow plugs cannot simultaneously fail. I yanked the controller off of the old blown engine (knowing that it was working correctly and was not damaged) and installed it on the motor in the truck.

Truck fired right up the first time. I cleared the codes and so far, after another *luke warm* start right after dinner, the truck fires just as well, if not a little better, than it did directly following the installation of the motor.

I have no idea what caused the controller to go bad, but obviously it was the problem. I have checked the wiring and a few other things to confirm that a short wasn't the cause, and found no other evidence of anything. Has anyone had thier controller fail yet?

 

glad you were able to fix it. hate that sick to your stomach feeling when you know it is going to cost some $$ and be a pain to fix.

 

where did you get the 6.0 repair manual??

 

Online. I have Dealer Principal access to FMCDealer.

 

NO WONDER YOU KNOW SO MUCH ABOUT THESE THINGS !!!!!!!

Would this be of help to anyone ?
http://www.backglass.org/duncan/ps60_manual/

 

Weather you know it or not you created a fault tree analysis of sorts, you once again demonstrated very good engineering practices/principals

 

There have been times that the 6.0 Bible came far more in handy than the shop manuals. The directions in the shop manual are step by step, but the illustrations are pathetic.

 

Hello psd 60L fX4. I currently own an 03 f350 6.0l crew cab up in Ontario, Canada. Have had truck into dealer 4 times for the same symptoms that you have just experienced and for the vibration issues that everyone else on these forums has seemed to have. Dealer replaced three glow plug control modules, within a three month time, before replacing two complete wiring harnesses and #2 and 5 glow plugs. Apparently, two glow plugs were shorted causing wiring harness failure. You may want to get your glow plugs checked before your problem happens again.

 

Ill keep that in mind. I have a spare set, and another controller so if it occurs again ill change both the controller and plugs. I believe it will probably be ok though.

 

WELCOME to the only Family Ford site.......please read the Guidelines
Then enjoy FTE

 

what vibration issues do you refer to? I guess I've not heard of them...

and 4 times for the same issue should generate enough documentation for a dsb or lemon law ...

Please enlighten us with your saga...

 

Well, funny you should ask. Here's some background on the truck. It was purchased August 03, and has a build date of June 03. 3500 km's from new, I noticed two vibrations, one when pulling from a stop in first gear (automatic trans.), it was a thumping in the center of vehicle until it shifts into second, and vibrations in the floor board at your heels between 1500-2000 rpms when accelerating and on decel. The first vib was finally repaired after the fourth visit. The fix was the maximum allowable shim under the hanger bearing that ford permits. The other vib has not been addressed to date. The truck now has 23000 kms on it, has a water leak by the parking brake mechanism, and an oil leak at the rear bottom of engine. I have put the call into Ford of Canada, and applied for the canadian version of your D.S.B, called Canadian motor vehicle arbitration plan. I have a meeting with these guys on monday, and i'm pushing for a new truck. Hard to believe that after all of these problems, I still love how this truck performs and all it stands for. Maybe all the 04's will be sold and I can hop into an 05. I will keep you guys posted with the results.

 

After the engine and all, nothing that happens will catch me off guard. Unlike others, I try not to blame Ford everything that goes wrong. If it goes wrong I will fix it; if its not worth fixing I will trade. If it blew up again tomorrow the truck is still IMO a great vehicle.

Mine has picked up a small oil leak at the rear of the engine too; maybe one or two drops per night. As long as its not gushing ignorning it will not bother me a bit. Kinda gives it a "retro" feel

Keep us posted...

 

Yeah.... but yours has been "tweaked" a few times
stacked tuners, methanol, 135 mph....
equala new engine !!!!
since you tried to blow up your original !!!
it's not like someone hasn't turned a wrench on it

 

Ok, you got me....