I Need Help
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Junior User
Joined: Nov 2004
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I Need Help
First, let me say this is my first post. I've owned nothing but Ford products for 24 years. I never had a problem until I ordered a new '04 F250PSD FX4 Lariat with EVERYTHING this year. My truck came in in April. I started having problems with the truck cutting off and running rough-- surging and rough idle at 2,000 miles. It has been in the shop 6 times now and has been in over two weeks now this last time. I made a mistake and installed a Banks 6-gun bundle (5" exhaust, tuner and chip) at 5,000 miles, along with a 5.5 inch Fabtech lift and 35" tires on 17" alloys. Of course the dealer now says the modification is the problem. By reading this forum, I see i am not the only guy with a problem with the 6.0! My service manager now says i will have to pay to have the truck returned to stock (to eliminate the Banks mods) so he can determine IF my truck has a problem. He claims the larger exhaust does not allow the EBP sensor and EGR to operate correctly. Any advice before I spend a bunch of money to return my truck to stock?
Post Fiend
Joined: Oct 2002
Posts: 11,314
Likes: 4
Firstly, welcoem to FZTE and wish you had come here earlier....
I think you either
a) have a VERY understanding and good dealer not to void your warranty RIGHT on the spot for bringing it in with mods like that on it...
or
b) are shining us on
or
c) have an incompetent dealer who doesnt know what he's doing so he's trying to work around you....
i just a guessin heyer
I think you either
a) have a VERY understanding and good dealer not to void your warranty RIGHT on the spot for bringing it in with mods like that on it...
or
b) are shining us on
or
c) have an incompetent dealer who doesnt know what he's doing so he's trying to work around you....
i just a guessin heyer
Elder User
Joined: Feb 2004
Posts: 920
Likes: 2
From: CA
Between 2-5K they never had a fix for your running condition/concerns? How many visits out of the 6 were when the truck was stock.. Any??.. Was there 'any' repair attempts done? Seems that if the condition was there 'prior' to the mods that would be a good argument in your favor.. Maybe another shop is in order.. Has it been to more than one? Can't believe that the lack of back pressure (although important) would make your truck 'cut off ' Seems that unless this is an intermittent condition, that 2 weeks should be enough time to point a finger at who's responsibility it is..
Anymore info. on what has been done.....
........................HP....................
Anymore info. on what has been done.....
........................HP....................
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Junior User
Joined: Nov 2004
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Well, let me clear a few things up for you: First, my wife works as the exutive assistant for the owners of the dealership. 
Second, my state's law says that Ford would have to prove that any modifications done to my truck caused the problem. Remember that I took the truck in BEFORE any mods were done. I will say that Banks has been supportive so far as well.
Second, my state's law says that Ford would have to prove that any modifications done to my truck caused the problem. Remember that I took the truck in BEFORE any mods were done. I will say that Banks has been supportive so far as well.
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Junior User
Joined: Nov 2004
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By the way, there seems to be more knowledge from guys on this site than all the Ford engineers combined! I appreciate the support!
It seems the problems can be traced back to the EGR valve and EBP sensor. My truck has the latest flash. Also, the dealership hooked up "the black box" or "flight rcorder" . I punched the button each time the truck acted up and it recorded.....NOTHING!
It seems the problems can be traced back to the EGR valve and EBP sensor. My truck has the latest flash. Also, the dealership hooked up "the black box" or "flight rcorder" . I punched the button each time the truck acted up and it recorded.....NOTHING!
FTE Leadership Emeritus
Joined: Jan 2003
Posts: 161,999
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From: 3rd Rock
Originally Posted by my04beast
By the way, there seems to be more knowledge from guys on this site than all the Ford engineers combined! I appreciate the support!
It seems the problems can be traced back to the EGR valve and EBP sensor. My truck has the latest flash. Also, the dealership hooked up "the black box" or "flight rcorder" . I punched the button each time the truck acted up and it recorded.....NOTHING!
It seems the problems can be traced back to the EGR valve and EBP sensor. My truck has the latest flash. Also, the dealership hooked up "the black box" or "flight rcorder" . I punched the button each time the truck acted up and it recorded.....NOTHING!
.... WELCOME to the site, please read the Guidelines… Check out the list of forums and make sure you read the headings and Read First: notices in each forum. Be sure to check out the 6.0 Bible…..great reading
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http://www.backglass.org/duncan/ps60_manual/
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Postmaster
Joined: Aug 2003
Posts: 4,483
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From: Central Texas
my04beast, there have been some problems with wire chafing on some models. There were some posts earlier with pictures where to look. There have also been some Ford Service Bulletins so your dealer should be aware of the issue. One of the issues is a wire looseness or shorting with the EP Sensor. The EP sensor is at the end of a tube that is located between the exhaust manifold and turbo. Is your downpipe (turbo to catalytic converter) a 5"? A 5" exhaust could cause lower back pressure readings and subequently incorrect performance by the VGT actuator.
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Freshman User
Joined: Sep 2004
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Check 'yer ICP sensor...
my04beast:
This was my truck's problem as found by the gurus at Ford Engineering:
http://dan.prxy.org/Truck/6L_bible_h.../Page_061.html
It is the ICP sensor, which stands for Injection Control Pressure. This was the goofy thing that was causing the surging, sputtering, coughing, big bursts of black smoke, yada, yada, yada. The put a "experimental" one on my truck and 1-1/2 months and 4,500 miles later, the truck is still running flawlessly. I was within 1 micro second of claiming "lemon" and immediate buy-back.
I am not saying that the ICP is your culprit, but I replaced EVERY other sensor with always the same symptoms and absolutely not fault codes...
Check into this and let us all know!
Jet-A
This was my truck's problem as found by the gurus at Ford Engineering:
http://dan.prxy.org/Truck/6L_bible_h.../Page_061.html
It is the ICP sensor, which stands for Injection Control Pressure. This was the goofy thing that was causing the surging, sputtering, coughing, big bursts of black smoke, yada, yada, yada. The put a "experimental" one on my truck and 1-1/2 months and 4,500 miles later, the truck is still running flawlessly. I was within 1 micro second of claiming "lemon" and immediate buy-back.
I am not saying that the ICP is your culprit, but I replaced EVERY other sensor with always the same symptoms and absolutely not fault codes...
Check into this and let us all know!
Jet-A
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Junior User
Joined: Nov 2004
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SBV45: Thanks for the reply. Yea, the dealer is aware of the wire harness chafing problem because I TOLD THEM ABOUT IT from information off this site. They swear thay have checked for this issue. By the way; I fat-fingered the keys when I said 5" exhaust. It's a 4" Banks monster exhaust with that huge tip! Thanks again.
Jet-A user:
The ICP sensor is a new one on me. I was convinced it was the EBP sensor but now I wonder...
Thanks!
Jet-A user:
The ICP sensor is a new one on me. I was convinced it was the EBP sensor but now I wonder...
Thanks!
Postmaster
Joined: Aug 2003
Posts: 4,483
Likes: 2
From: Central Texas
Describe the symptoms again. What happens under what conditions. Does it happen mainly at an idle? Are there different symptoms? I understand that the symptoms existed before any mods. Did the symptoms change after any mods?
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Junior User
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SBV45: The symptoms are surging at highway speed; i can set the cruise control at 60 and the truck will speed up and slow down on it's own. You can feel the truck accelerate noticably, then let off...just like you are mashing the go pedal then letting off...continuously. The most embarrassing symptom is when you roll to a stop, the truck acts like it's running on 4 or 5 cyls, blowing black smoke then it "surges" like the computer is trying to compensate for something. If you don't have the brake pedal mashed, it will run over the car in front of you when it surges!
Postmaster
Joined: Aug 2003
Posts: 4,483
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From: Central Texas
According to the Ford Service Manuals Diagnostic Charts, here is what they list for surging while cruising:
Symptom:
Lack/Loss Of Power
Runs Rough
Misses
Buck/Jerk
Hesitation/Stumble
Surge
Additional Driveability Concerns: Poor Fuel Economy
Note: Perform the following preliminary checks:
Confirm brakes are not dragging.
Check for oil in coolant.
Check engine oil level.
Confirm oil change within 12,070 km (7,500 miles).
Check air intake system: Air Filter Minder.
Check MAP sensor hose for holes, blockage, or disconnection.
Check EBP sensor tube for holes, blockage, or disconnection.
Check intake manifold system for leaks.
Confirm acceptable SAE oil viscosity and API rating of oil.
Check for sufficient clean fuel.
Check for air in fuel.
Check for intake restriction.
Compare loaded weight of vehicle with performance expectations.
Power monitor active.
Transmission concerns.
Then there is more detail regarding the components and tests.
Symptom:
Lack/Loss Of Power
Runs Rough
Misses
Buck/Jerk
Hesitation/Stumble
Surge
Additional Driveability Concerns: Poor Fuel Economy
Note: Perform the following preliminary checks:
Confirm brakes are not dragging.
Check for oil in coolant.
Check engine oil level.
Confirm oil change within 12,070 km (7,500 miles).
Check air intake system: Air Filter Minder.
Check MAP sensor hose for holes, blockage, or disconnection.
Check EBP sensor tube for holes, blockage, or disconnection.
Check intake manifold system for leaks.
Confirm acceptable SAE oil viscosity and API rating of oil.
Check for sufficient clean fuel.
Check for air in fuel.
Check for intake restriction.
Compare loaded weight of vehicle with performance expectations.
Power monitor active.
Transmission concerns.
Then there is more detail regarding the components and tests.
Freshman User
Joined: Sep 2004
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Originally Posted by my04beast
SBV45: The symptoms are surging at highway speed; i can set the cruise control at 60 and the truck will speed up and slow down on it's own. You can feel the truck accelerate noticably, then let off...just like you are mashing the go pedal then letting off...continuously. The most embarrassing symptom is when you roll to a stop, the truck acts like it's running on 4 or 5 cyls, blowing black smoke then it "surges" like the computer is trying to compensate for something. If you don't have the brake pedal mashed, it will run over the car in front of you when it surges!
Got the ICP replaced and voila! Fixed & un-neutered.
Oh yeah, I forgot to mention that my fuel economy went from 15.54 mpg to 17.32 mpg...
And that saves me about 19.8 gallons per month, and depending on the diesel price of the day/week/month, that can be a pretty good time at the bar... What's also nice is that with the 38 gallon tank, I can now go a whole week between fill-ups! Nice.
Couldn't hurt to check it out! I guarantee that Ford already knows about this fix and they need to educate your Area Rep. & Service Manager.
--Da' Jet
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Junior User
Joined: Nov 2004
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Thanks Jet. I called my service rep and told him to replace the ICP. He wouldn't take my advice at first (so many of these guys sit on the throne and take it personally), then I told him I'd pay for him to do it if Ford didn't or if it didn't fix it. He agreed. I'll let you know what happens.