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My 2004 6.0 just was running perfect until I recently passed 40,000 miles. I started it up one morning and I could barely hear it - it really sounded like it was about to quit everytime I let off the gas. After about a week of this it began hesitating severely during acceleration, and finally it failed to start. I was able to start it after 45 minutes of trying, and its run terrible ever since. Also, noticing decline of about 4 mpg over last two tanks (about a 25% decline). Dealer replaced something with the exhaust that was on a recall and told me that would take care of it - truck still running the same but hasn't left me stranded yet. Problems seem to be intermittent. Any ideas? EGR valve - could that do all of these things? Would it be possible for my truck to have more exhaust odor since this started or is that just my imagination? Thanks -
Thanks for the input - I've also noticed now that when towing my boat the engine downshifts earlier and struggles to lug up hills I managed without a downshift before. I'm going to take it in again this week.
Last time I took it in (before the recall replacement) they put it on the computer and told me nothing was wrong. It quit on me 2 hours later. I've got a feeling I'm going to get the all clear thing on my next visit also. Part of the reason for being here is to get a few ideas that I can question them on when I go back. Thanks -
Update - finally quit altogether today. No check engine light, but simply won't go when the accelerator is pushed, and the engine sounds like a 5 hp outboard motor. I spent an hour with the mechanic at the dealership and noone has a clue. The EGR valve is caked with soot, but seems to be functioning properly. We couldn't start it after I turned it off, so they towed it into the shop to work on it tomorrow. I'll post another update when I get some answers from the dealership.
sounds like a horrible dealership, Ive learned these 6.0's need good techs, and they seem to be hard to come by in alot of places. Hope they can get it running right for you though.
Update - finally quit altogether today. No check engine light, but simply won't go when the accelerator is pushed, and the engine sounds like a 5 hp outboard motor. I spent an hour with the mechanic at the dealership and noone has a clue. The EGR valve is caked with soot, but seems to be functioning properly. We couldn't start it after I turned it off, so they towed it into the shop to work on it tomorrow. I'll post another update when I get some answers from the dealership.
Are they Certified 6.0 Technicians? If not, you really should locate a Ford Service Dept. that has them. You and your PSD will be much happier in a much shorter period of time!
Picked it up today - they changed the EGR valve, throttle plate, and a wire that connects to the throttle plate. It seems to be running perfect now with none of the symptoms I had for the three weeks until it finally quit altogether.
Our dealership is very good - I've had good service there this time and all of the other times I've been there for routine maintainence, etc. The mechanic there is certified on the 6.0.
Hopefully this will fix the problem. They're going to hold my ticket for a week or so to give it time to act up if its going to. So far, so good.
Now nearly 2 weeks out - running perfect. I make a 80 mile round trip every Wednesday for work, and averaged 18.6 mpg today. Before repairs last week, I got around 13 on 2 different trips to the same place. My truck seems to be back at its "like new" baseline. Thanks for the help - -