I have done some searching on this and I have not as of yet found anyone whose symptoms match mine.

I have an 04 Excursion LTD 4x4; 6.0l PSD; Edge Juice w/Attitude; EGR disabled; Throttle plate delete; cat and muffler delete.

What I am experiencing is an intermittent rough idle when hot. Usually after an extended run at 70-75mph; but not always. When I come to a stop; at a light or in my driveway the truck idles down then the idle floats between 610 and 700 rpm and is quite rough. If I'm in a position to take of again; after a couple of throttle applictaions the condition usually goes away and may not return for a few days or weeks. The truck runs fine at speed and any throttle position off idle. I am experiencing no surging or bucking or any other symtoms. My oil level is good (2/3 up on dipstick) and my boost pressure is normal.

If anyone has any thoughts as to what direction I should go in terms of diagnosing/fixing this problem I would greatly appreciate them.

Thanks

Jason

 

Your username is amazingly close to mine as our symptoms of a problem I've had. My X is bone stock (but looking at minor wheel tire upgrade! )

Here, in chronological order, are some posts I'm made.

To date I have not had a repeat problem. I'll be waiting for the colder months next year to see if we have issues again.

The last fixes were replacement of 4 injectors, then a fuel pump after failure, and finally the Inductive Heating flash.

Hope you get yours worked out!

Last post in this thread describes problem similar to yours:
https://www.ford-trucks.com/forums/5...le-miss-3.html

https://www.ford-trucks.com/forums/5...d-problem.html

https://www.ford-trucks.com/forums/5...ked-today.html

 

Thanks for the reply; the idle issue you were having before you did the injectors sounds exactly like what mine is doing (btw your video was perfect). How bad did it have to get before your dealer was able to diagnose it?

I use my truck for work and have a hard time justifying giving it to the dealer for a long period of time; not to mention the $100/hr charges just for diagnosing; especially if it mean 4 or 8 new injectors. Sadly mine is out of warranty as I've already got 175000km on it.

Do you know how the dealer diagnosed the problem? Or managed to replicate it? I can't even repeatably reproduce the problem myself let alone try to get a dealer to. Maybe I can give mine some direction and expedite the process a little.

My truck was a little earlier build that yours, 01/04 but our problems are strikingly similar; I've had EGR plug ups a couple of times; and I discovered this winter that my EGR cooler will leak if I let the block get cold (-15C or lower); usually it is garaged or plugged in so I never noticed before. I also had #5 injector replaced at around 25000km. Other that that the truck has been pretty well trouble free. I hope you're enjoying yours as much as I'm enjoying mine.

 

We have the same problem.A friend ford tech went through the truck and swapped injectors as the truck was throwing codes for four injectors but all were good.Fords tech in detroit guesses that wieing (checked ok) or egr cooler or head gaskets that are the problem misting the enough to foul combustion .I have no coolant loss and the coolant comes up to temp evenly.A friend of mine who is a hd forman at a mine suspects it is the valve cover gasket as it has wiring in it and has been seen many times on f450s-550s that are in service on the mine site.I will have mine changed next week and let you now how it works out on this thread.2004 6.0 350 sd crew stock

 

I was originally suspicious of the EGR myself; that was why I diconnected it and removed the throttle plate. That made no difference whatsoever in terms of the idle problem. I've been through the coolant system in detail and kept track of coolant levels; signs of blow back etc and found nothing abnormal.

Good luck with this; I hope you get it figured out.

 

04Xcursion,
There was no concrete way to duplicate my issue either. The highest probability I had was to drive it for at least 45mins (I am not kidding when I say it was happen almost up to the point I pulled in front of the service bay doors once).

Utimately, I let the dealer have it over the course of a week. They capture the event during a power balance test and found that certain injectors were dropping out at idle. After (left bank?) injector replacement the power balance test result were much tighter.

Shortly after injector replacement I had a fuel pump failure. Coincidence? Who knows...?

Since injector and fuel pump replacement, things have been pretty good. I thought I had a stumble on a VERY wet, driving rain trip home one time but it hasn't happened again. Am I convinced we identified the root problem? Not really, but only time will tell.

Next on my list is a turbo replacement. The tech diagnosed a possible turbo vane sticking issue on a test drive. This does not surprise me since it's on it's 3rd EGR, 2nd EGR cooler, and had the intake cleaned due to 'wet, sooty' conditions. However, they informed me that if I wanted the turbo verified I had to be ready to pony up ~$780 to cover the cost of cleaning and a (certain) part replacement if they tore it open and found no defective parts. Defective parts = repair/replacement on Ford (-$100 deductible). However, I have others telling me it should be covered no matter what.

Anyway...I'm still holding out a lot of hope that I'll get this vehicle squared away and all these issues will be a thing of the past. If mechanical things can break, they can be fixed, right!?!?

Feel free to hit me up with questions. I'll relay my experience(s) as best I can.

Take care

 

Apparently, I spoke too soon and things aren't squared away. Back in the shop this week for the same issue.

Luckily it happened by the dealer and I was able to get the tech in the vehicle with me. He experienced it and has some ideas (icp, valve?, etc...). However, as soon as we pulled in his bay to go hook it up to the computer it started to run normal.

I fear I'm reaching the end of my rope with this thing. Maybe I'll have a more fresh outlook tomorrow.

 

I feel your pain; intermittent problems are a nightmare; I've been on the verge of taking mine in serveral times; but as soon as I make up my mind to do it the problem clears up.

After doing a lot more research I'm strongly leaning towards the ICP sensor myself. Although usually ICP problems seem to be more pronounced and not intermittent (except in the early 03 builds where they were plagued by wiring problems).

The strange thing about the problem I'm having (and you too from the sounds of it) is that it doesn't seem to getting worse (or better) it just appears and then disappears for no reason.

Thanks for all your help; it is much appreciated. I really appreciate all the folks on the forum who are so willing to share their knowledge and experiences.

Good luck and keep your head up; you've got a good truck it just happens to be a litle quirky. Let me know if they find your gremlin.

 

I will definitely keep you informed. I actually dropped it off today b/c it was running so cr@ppy that I wasn't going to drive it anymore this week anyways.

Yeah...it's mechanical, and anything mechanical can be fixed, right?!!?

O/C...it could be electrical. As soon as we hit the horn to actuate the service bay door it started running like a champ! We kinda chuckled...

 

to both of you, i would go with icp sensors. i have put alot of 03 style icp sensors on due to oil seepage causiing what yll are saying. i have also had a few with the icp sensors in the head shorting out causing the truck to do all kinds of things. 04x, i may have even suggested this to you. without having a spare engine floating around, i would not try it without catching something live first due to the price of the icp sensor.

 

BTH...yep...that's what the tech is thinking...icp. I'm sure he'll hook it up to the computer, but history has shown it doesn't throw/store a code...why? He said he'll probably just end up throwing a new one on anyway. I have to check my vehicle history b/c I thought I had one replaced already. He also said (some) valve, but I didn't catch the first part...although I'm pretty positive he didn't say EGR (I would have recognized).

Thanks again BTH, your experience is much appreciated!

 

well depending on what he is checking it with, there wont be a code. if it shorts out there will be a pending code of some sort unless it is shorting out the pcm as well.

 

Hello all,

I did a search but there are too many results hitting key words "injector" and "pressure", so maybe you can help me out.

Same issue as above. To recap:
Reoccuring issue...sputter/miss, usually at idle, after warm sustained drive on highway (+30mins).

Dealer has has vehicle since last Tuesday. Tech experienced, but it stopped before computer hook up.

Progress to date:
Called dealership and tech is saying he has a response from Ford to replace an "Injector Pressure Regulator" (Fuel Pressure Regulator?). Does this sound plausible? I'll try to get more details.

 

i feel like they are on the right track. if the irp wont fix the issue, it will probably be a harness. sounds like they are trying to get to the bottom of it.

 

BTH,
Yeah...I hope we're getting there. I'm just suspect because it's been the same issue for a while now.

I will ask the dealer/tech the same questions, but 1) What is the purpose of having to contact Ford and/or to await a response from Ford before moving forward with work? I suppose it could be any # of reasons (warranty authorization, diagnosis help/troubleshooting, etc)...?

EDIT: I'm starting to wonder if it's something electrical. I know this is WAY out there, but it was uncanny how firing the horn for the service bay door and the engine going back to running 'normal' coincided. It was probably totally coincidence, but we both kind of looked at each other when that happened.

I have that pesky digital climate control cluster 'dead' on rare occassion too.