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Thats very strange. It really sounds like fuel pressure, but it could be something unrelated. I wonder if for some reason the fuel pump is not turning on when you turn the key on and that is why there is no pressure.
Well, the only way to find out if that is the problem is to put a pressure indicator in the fuel line somewhere to see if that is the problem. Other than that I have no idea what to do next. I would say to let the Ford dealer find this one.
Mine did something similar for the first time yesterday. Went out from work, truck been sitting for 8 hrs. 60deg weather and damp. I hit key and it did not crank. Tryed it again and it turned over quite a bit before it started. When it did start it blew white smoke. Drove home just fine, went in for bout 20-30 mins., went back out with wife and it started quickly but had a "burp" sound, almost like a timing thing thru the intake. (not sure if it was intake or exhaust the noise came out of.) We went and eat, came out, no problem. I went out this morning and 5x it started perfect.
Mine may be unrelated and maybe was an injector with trash??? or something???
it does sound like a fuel problem, could be fuel pump losing it's prime. fuel regulator letting the fuel drain back to the tank. you see if the dealer can not duplicate the concern they can not fix it, that is why they say they can't duplicate it. if they start throwing parts at it to try and fix it they are saying their is a concern with the truck and if they don't fix it with in three visit to the dealership then in most states thahts when alot of people start talking about the lemon law.all so if they dont fix it with some of the parts they were just throwing at the truck Ford cuold refuse to pay for repairs under warranty, thats is why they won't start replacing parts untill they are sure they know what is wrong with it. so you see if is an interrmitten problem with the truck it makes it hard to fix. I would sugggest leving the truck with them for a few days to see if they can duplicate it. or ask about putting in a flight recorder in the truck to record off the PCM when it happens again.
I am trying to get an apt with my local dealer. They have great tech there that I am holding for. Mine has got worse now over the last few weeks, and now a buddy of mine with his 05 5.4 is having the same issue, just not a frequent.
fuel pump is your likely culprit. either it is going out or is somehow not getting a decent suction. it basically sounds like your trucks are be starved due to inadequate fuel rail pressure.
I had a U-Haul truck do exactly what you guys are describing until it quit completely. The company came out and replaced the fuel pump on the spot and the truck fired right up. Never did it again.
until the issue is resolved, a good idea would be to prime the fuel rails 1 or 2 times before you start the motor. take the key to the "run" position but do not start the motor. after ~10 seconds, rotate the key back to "off" and take it back to the "run" position. after another ~10 seconds, start the motor.