At 1,800 miles I've experienced the first problem with my truck (04/04 -11/03 build 6.0). I Started the truck this morning and let it warm up for a couple minutes. After backing out of the driveway, I only made it about 400 feet, coasting down the long hill to the main road, before the truck started to run really rough. At idle the truck is now very loud (I should mention this truck is still equipped with the quiet idle- not true PI but ICP/EGR manupulation), and idles like it has a 3/4 cam in it (rocks back and forth).

Driving down the road is not much better. No power and after the truck shifts into 4th or 5th it bucks, surges and shakes and feels like it has a square tire at low rpm (under load). I think this shaking may be congruent with the torque converter locking and amplifying the rough running engine. Drove the truck about 8 miles to the dealership and dropped it off. The service dept is closed today (big fishing derby weekend) so I droped off the key, and will wait till Monday.

Any ideas, suggestions? Checked the oil level for diesel, and it looked fine (middle of the hatch marks), water in fuel light never came on, and I just recently drained it 800 miles ago. Possibly an injector or bad ICP?

Hopefully it will be an easy issue for the dealer to resolve so I can go back to enjoying my truck. Any ideas/experience would be appreciated.

 

EGR, ICP, VGT or EBP---those seem to be the recent culprits for the issue you are saying--or an injector, but hopefully NOT that.

 

+1..........

 

Thanks for the replys,

Guess I will find out on Monday. I suppose I could of tried disconnecting the EGR to see if it resolved the problem. Whatever the problem, I'm almost positive the truck is not running on all eight cylinders, or at least it feels like that throughout the rpm range. Makes me wonder if it could be a bad ICP sensor, as the truck is idling very loud at idle and no longer has the quite idle (ICP manuipulation) that disappears at tip in. Hopefully not an injector.

When the VGT and EBP sensors go bad does it create similar problems (ie feels like the truck has dropped a cylinder) or just surging? I have never had any service work performed at the dealership I bought the truck from, which is also the only Ford dealer for a couple hundred miles, so I hope the techs are up to snuff on the 6.0's.

Whatever the problem, I still love the heck out of this truck and still don't regret trading in my dmax for it.

 

What build date?
What is your vin?
Check your oil level. A high oil level and a steep driveway will turn your oil to foam making injector operation erratic.
Reboot your PCM by disconnecting both batteries.

 

Bob-

Truck is an 11/03 build (2004 motor) so I'm not real worried about injectors, as they are C95's. However, anything is possible.

The oil level is fine. I performed the inital oil change at 1,000 miles. Filled with 13.5 qts. which puts me in the middle of the hatch marks. I checked the truck after it started acting up and the oil level had not moved a bit.

 

IMO re-flash the PCM, you already have he same flash they would put in it...seems to me a PCM problem….like a bit flip!!!

Have you ever stopped as soon as it happens...turn off and restart???

 

It sounds exactly like what happened to mine, and it's an 04/04. They replaced a bad #1 injector and the fuel conditioning module. This was at 90 miles and it's ran great since. Good luck.

 

This from Ford:
Possible culprit.

 

Yes, once the truck started running poor I shut it down and restarted it a couple of times, with no luck. Whatever happened is not intermittent, as it started and never stopped.

Thanks for all the ideas/suggestions

Hopefully, my dealer will have no problem resolving the issue, but if they are stumped you've all given me some leads that could be the cause(s).

 

Please keep us unformed, it will be another thing we can all learn from.

 

Any update?

 

Just got back from work a few minutes ago, and walked in the door. So here is what I found out today. I talked to the service manager this morning and discussed my symptoms. About two hours later, the service manager called and confirmed that the truck had dropped an injector (did not mention the cyl#). Good news is they found the problem. The bad news is that they do not have any injectors in stock, and had to order one via priority courier. Due to my location in Alaska, the couriers (Fedex,UPS,DHL,etc) will not guarantee overnight delivery, and overnight usually means 2-3 days. Fedex is the fastest and UPS second day air always takes 4 days!!!

The service manager was very accomodating and asked if needed a rental to drive. I told him I'd call thursday to check on the status of my truck.

Huntercgr- looks like the same thing you experienced. I will double check to see exactly what cylinder # it is.

In retrospect, I do believe the injector was bad from the factory. At about 100 miles the truck idled like this for about 3 seconds at a stoplight, then returned back to normal idle. At the time I just chalked it up to a bit of bad fuel, or a quirk of a new engine that had sat on the lot for close to 6 months, having only 18 miles logged on it during that timeframe.

While it is a bit frusturating to have this happen at 1,800 miles, these are machines assembled by man, and overall I look forward to many trouble free miles. Overall I'm really happy with the truck and can't wait to get it back.

 

Excellent attitude. Even the C95's have a certain failure rate. Anything that moves quickly and repeditively under a lot of pressure can fail.

 

Kewl, at least they found the problem quickly, a good sign IMO. You might ask if they get any secondary fuel system codes.