I have a 2004 6.0 I am not sure of the the build date. Every once in a while the truck sounds like it is going to stall and sits there at idle and spitts and sputters it only shut off once.
This only last for a few seconds and then it jumps back to regular idle. I have been back to Ford more times then I prefer to mention. They have replaced just about every wiring harness and sensor I can think of right now. And to no avail the problem still exsists. Every once in a while at about 45 mph at a steady speed and a steady rpm it will do the same thing and then go away. There is no black smoke or any smoke for that matter.
One good thing, Ford is not making me pay the deductable on the extended warranty. Just took it in 2 days ago again and there were 3 other trucks in the lot with the same problem. We all were standing there with hoods up and the mechanics standing there scratching there heads. This seems to be a common view of my truck with the hood up.
Very frustrating when you pay this much for a vehicle and they say they don't have any ideas.
Does anyone seem to be having the same problems, or does anyone have any ideas???

 

coderis,

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Surely your dealer has checked oil level...mid to lower hatch marks on the dip stick after the dip stick is fully seated....yes?

Type of oil?

 

I do all my own oil changes and check my oil in the motor and the trans all the time. I use rottella oil. Used to use Pennzoil but it was getting to hard to find. Had the same problem on both oils.

 

My dad has had the same problem. Ford dealer has done all kinds of fixes with only temporary success...problem still exists.

 

Use Mobil 1 Truck Suv oil All 15 Quarts!!

 

Your truck may not exibit all of these systems:

2003-05 Various Running Problems, Check Engine Light; New EBP Sensor:
Trucks built before 1-17-05 that exhibit buck/jerk, hesitation, lack of power, stalling, stumble, black smoke, surging, rolling idle, changes in engine sound at idle or when driving at a steady speed, or with the trouble codes P2263 or P0299, may have an exhaust backpressure sensor signal that is incorrect or erratic. A revised EBP sensor is available if this is found to be the case. Part number 4C3Z-9J460-A. Broadcast Message 3815.
Normal EBP signal reading should reflect atmospheric pressure with the key on/ engine off. Typically, this is 14.7 PSI/0.88-0.9 volts at sea level, decreasing one PSI/0.10 volt for every 2000 feet of elevation. It should be within 0.5 PSI of BARO and MAP sensor pressure signals.

I would guess that your dealer has replaced this but, thought I would post it anyway.

Are you in the PA mountains by any chance?

 

My truck has the same symptoms as yours does. I have an appointment in 2 weeks to have it addressed. Hopefully they can figure it out.

 

I live about an hour northwest from Phila. Its getting to the point where I am thinking about trading it in for a new one that has all new parts and peices and hoping that I don't have the same problem.
The problem only exsists at an idle or trying to hold a constant speed around 45 mph. any faster it doesn't happen.
I pull a 33 foot fifth wheel and you would never know there was a problem. Love the truck and it has more ***** than you can imagine being stock.

 

Similar problem, just got it back today w/ brand new EGR valve of newer design that was told Ford just came out with, old one was erratic & plugging with carbon buildup, also they just did a brand new recall on the EP sensor & reflashed w/ another brand new recalibration - seems to work much better in the first 120 miles today, milage is up about 2 mpg from last flash, so far, I'm very pleased, good luck

 

its funny ... just registered yesterday on this site because i was having same problem with my 04. hoping i would learn something about it. I have a bully dog power hound coming in on tuesday and im thinking i should hold off on the install until after taking it into ford. has anyone run into issues with exhaust and warranty? i just put a 4" magnaflow on and am worried about that stopping any work that might be covered.