Hi
Instead of answering all threads on 6.0 issues, I am putting the info my dealership found in this 1 thread for everyone to read. I took my 6.0 to the dealership last week for a surging issue which was getting worse. They had it for a few days and of course it didnt surge. But the tech hooked up something to the truck, and shazzam it surged. Here is the info from my bill/customer copy of what was done:


ICP pressure spikes to 4200 psi then returns RO normal replaced faulty sensor retested ok, had a continuos code P2263

This was what they put on the form. They also did safety recall 05S34. I put on roughly 250 miles on it, driving in heavy traffic with 95+ degree temps outside, highway driving and local driving at different times of the day. So far so good. The dealership is going to call me to check on the fix, if things are fine tuesday, they will start checking the ICP's in the 6.0 trucks that have the same stalling problem. No perfromance loss and the MPG seems the same or a little better, but thats my small observation only.

This find was a 1 in 1000 shot of seeing the ICP spike. My question is what is the regular PSI for the ICP?

 

I'm glad to hear they may have found your issue. I will have to look thru my paperwork about the ICP, I am not sure if they replaced it on my last go 'round. All I know is that I am approaching about 2000 surge/stall free miles so far and loving it! My last time in the replaced the engine harness, the FICM harness and the EBP. I think I remember something about the ICP. I do remember someone else either on this board or another one that had our issue and had the ICP replaced and they were running good too.
Keep us all updated on the fix!

 

I picked my '04 up from the dealer yesterday after taking it in for the recall and the stalling issue, which had gotten quite bad. They repaired the harness per recall 05S34, replaced the CAC tube per recall 05B29, and replaced the exhaust pressure sensor per recall 05E15. According to them, in order to fix the stalling they repalced both the ICP sensor and the EGR vavle(3rd time with the first 2 times being attempts to fix a problem actually related to the VGT sensor). All seems good now and it runs like new .

 

I just had all those recalls done, plus egr/pcm flash about 10 days ago. I just got back from Florida, and while down there experienced a dead pedal/stall? at about 25-30mph, the engine never stalled, just got no response for that moment.

On the way home, my first fuel stop the engine idled, and sounded rough (egr valve?). My second stop, same thing, this time check engine light came on.

I've had no problems up till now, and these events had no effect on the way the engine performed, or my fuel economy.

Made an appointment with the dealer, not thrilled with this chain of events.

 

So far so good. Keeping my fingers crossed still. But very happy that the tech saw the spike. The dealership called me today asking how things were, they never did that before. I told things were working fine so far. They will now look at their other trucks in service complaining of stalling and other item. Checking the ICP and looking fo those codes.

 

Well, this morning the truck stumbled and did little surges 4 times while heading into work. Took it immediatley back to the dealership. 12 months of dealing with these diesel problems. The tech feels since these issues I am having are electrical. The truck is unsafe. To get Ford to listen I might have to go to a lawyer, dont want too. Just want to work it out with them. The service manager was supposed to call the District manager and get a tech out there. Thats what they told me.

 

Sorry to hear that!! They need to think seriously about doing the engine harness. I have put over 3,000 miles on mine now since they did mine and have not had one surge/stall yet. It is running flawlessly (knock, knock on wood) It is actually fun to drive it again! Good luck

ps. Make sure they do both the FICM and engine harness.

 

They did the recalls a few weeks back and replaced the ICP sensor, been fine since until this morning. The one thing that did stand out is the EGR vlave was doing alot of moving while stopped or at idel, sound of the engine changed when it moves. Wonder during the movement the EGR doesnt fullly open or fully close thus causing the stumbling and surging. Just a off the wall thought.

 

Yeah, I remember reading your posts on here awhile back. Your truck sounded like it had the same exact symptoms mine did. Sometimes it was almost like a gremilin was under the hood playing with the throttle, scary! I agree with your tech about it being an electrical problem. I honestly think they have a rash of bad engine wiring harnesses out there and they are starting to realize this. This is not part of the current recall out there, that is just the Fuel Injector Control Module wiring harness. It was just kinda weird how mine got fixed. The last time mine started surging (20 miles down the road after their last attempt to fix it) I called them and told them I wanted to bring it in the next time a Factory Ford Diesel tech would be there. I dropped it off. The next day my advisor calls me and tells me that, of course, it did not repeat the symptoms. The factory tech did some tests on it and said he found some codes which related to an electrical short problem in the system (why couldn't the dealers techs get this code from the system on the 3 other times I had it in there for the same problem?). The Ford Diesel tech authorized them on the spot to order a engine wiring harness and change it out! Not just look for problems, but to change it out. I talked with the mechanic that did the work and he saw bad areas on the harness that could cause shorts. They billed Ford $1000 for this job. Tell them my story, hell, have them give me a call!

 

Awesome, I asked for the tech to come out this morning. Told them enough is enough. I will tell them of your situation and hope I get the same response and fix. Lets see if they do that. Very frustrating spending big $$ and worried when driving if that gremlin comes back at a very bad time.

 

Now...let's fully understand, but I may be way off base on this; However, my understanding is that during idle conditions, the EGR is supposed to be fully closed. When ever that is not the case, on a gasoline engine, atleast, the engine will stall, and/or, run extremely rough. It's like having a very large vacuum leak.

 

Your right about the EGR valve being closed at Idle on a carberated/TBI gasser. They will stall or run very rough. I think this is because the fuel mixture will lean out like a vacuum leak.
The EGR on a Diesel will act different if it is stuck open because it just lets exhaust into the intake air after the turbo. It won't change the fuel mixture.

 

3/4 I had your problem and the engine gave code P0404 found EBP sensor bias high readings and EGR stuck open

 

Back to the dealer, codes P0488 (software issue related to egr flash done last month), P1408? They replaced egr valve (binding due to carbon buildup), everything fine now. Egr valve is a new design.

Dead spot in throttle, they found nothing, apparently didn't set a code.

 

So, my question is that the operation of my egr opening and closing during idle and when the truck is in gear and stopped is not normal? Seemed like every 5 to 8 seconds it would either open or close. You can tell by the sound of the engine noise being quiet and noisey ( which I like).