I was having stalling, engine cut out issues, no start issues and so forth. Ford could not tell me why this was happening and even put a flight recorder in it to try and figure it out - They deemed it had to be cause I had the wrong oil in it and way over on my miles - (not the case!! Rotella 15W 40 and only 3400 miles) SO they looked at the recorder and still could figure out WHY??? So they decided that they are going to replace the wire harness.......Seems like - NO THEY ARE still shootin' blanks at what the problem is....AGH... My truck has been in for 2 weeks now - I dropped it off last friday and hopefully will be able to pick it up tomorrow...... What concerns me is replaceing the wire harness - that is a huge thing and after all this I fear it still won't be right.....

Oh yeah - 2004 F350 4x4 Crew Cab Lariat 6.0L Automatic Short box

 

Good to hear from you again. I'm glad to hear that my thought about the wire harness is something they have considered. Mostly it's just plugs. So don't worry too much. Be sure and let us know how it rides tomorrow.. It would be nice for once to hear if our advice actually worked.

Best of Luck,
Corey

 

FOR SURE I will let you know if your advice worked!!! Thanks so much!! I just want my truck back!! They have me driving a 03 Focus - YES A CAR I wanted them to let me take one of the new 05'2 for a rental but couldn't quite convince them of that!!

 

My '04 is in the shop for wiring harness now, it is the only Ford engineers can come up with these days as to why they lose power, cut off, etc. The Service Managers 03' quit running on him and I thought that was just too funny except it stranded him about 250 miles from home and they towed it back to his dealership. Put on a wiring harness and now his is running fine again! For now!

 

mnfordchicksounds like my old 2003/6.0,bought it new Aug '03 at about 4500 mile it starting jerking, bucking and would die on me. They replaced TMC,FIC and the TCM even brough in the regional ford mechanic and he couldn't at frist figure it out. It was a shot in the dark they replaced the entire engine wiring loom, problem went away. Dealer told me mine was the first 6.0 to have this problem in the country

 

Well not the only one in the country anymore!! Hopefully this will solve the problem!! I am thinking I may trade it in for a 2005 and hope the problems are minimal.....Thanks for your input though it is interesting to hear other peoples story about these 6.0L's

 

This is a known problem and has been for a while. Here are some bulletins from Ford:

Wire Chafing Issues:
A variety of driveability issues can arise from chafing/shorting wiring, such as crank/no-start, stall, running rough, misfire, buck/jerk or lack of power. The most common location for this is the valve cover/cover bolts near the FICM or the intake manifold bolts where the harness routes under the air intake hose. The harness should be rerouted and any chafe points insulated with rubber vacuum caps. Other chafe problems can occur where the sensor harnesses route around the valve covers, thermostat housing, idler pulleys, glow plug relay bracket, and near the accelerator pedal assembly (adjustable pedals), and also near the PCM by the battery and near the relay box brackets at the left rear corner of the engine compartment. On Econolines, also inspect at the top edge of the computer, along the oil dipstick tube bracket and auxiliary A/C lines. Broadcast Messages 1407 and 3077.

Wiring Harness Chafing:
Some 03/04 trucks with the 6.0 may exhibit a crank/no start, rough running, misfire, buck/jerk or lack of power. This may be due to the FICM harness chafing on a valve cover stud near the FICM. Other potential locations for chafing are where the harness routes past the EBP sensor, the belt idler on the driver side of the engine, the glow plug control module bracket on the passenger side of the engine, and the accelerator pedal sensor wires at the steering column (adjustable pedals only). Reroute and repair the harness as necessary. Broadcast Message 0918/1374, SSM #17522.

Do a search on this forum for wire chafing. Ford even put out pictures on the tech website to show them where to look. This dealership seems technically challenged. If possible, find another.

 

OK - Picked my baby up this morning after a week of not having it and it is running OK.....I asked them how confident they were is fixing the problem by replacing the wire harness - he said "fairly".....I asked if he could see anything wrong on the other wire harness and he said nope and that's what worries us. Well they wanted to take and run a few miles on it today to make sure it was going to run properly - I told them I needed the truck back and it didn't matter who was rackin' up the miles, if it is going to act up again it is and more than likely you (the dealership) would not be able to fix it anyway.....If it does act up again they can buy it back and I will get anohter one.......

 

This fix should be very stright forward....

 

So you think that this has solved the problem??? For good??

 

IMO from what I read the problem is and how they fixed it yes.....AGAIN form the data here...yes
and you understand I squirm a bit when you ask forever…ug…is anything forever

 

that's funny!! I found out how to possibly fix the problems from this site before the mech could and I am a WOMAN!!!! I think they think I am stupid - This ain't my first day around a diesel!! Thanks everyone for your expertise help !! MUCH APPRECIATED!!

 

The combined knowledge of this forum is unreal; we are greater than the sum of our parts.

Good luck!

 

After all this.....and just driving it out during lunch I am now realizing that when jsut going down the road staying at a constant speed you can hear it idle up and down, the rpm's stay put but I can hear something like the idel sound reving up and down - now what is this about???????

 

I have knowledge of this part too.. My Jan 03 has done that since it was brand spankin new. It's never enough surge to make the tach change, or to move the truck. I have no idea, I just let it be. I've seen gassers that have an idle that isn't smooth but doesn't surge enough to move the tach. I figure if it breaks. Then I'll let them fix it. Just enjoy, I mean if it's not affecting anything is it really that big of a deal??

Best of Luck,
Corey

*Parts Changers*