I'm about to buy another truck but don't want to, just want mine to run correctly. Here goes...
I have a 2005 6.0L. Dealership cannot find any trouble codes so they think it's running great. This truck seems to be exceptionally noisy in the engine compartment, louder than my 7.3 ever was. Also, my engine fan runs full blast anytime I'm accelerating, even when the a/c is turned off, even when I've just left for work and isn't up to operating temp, even when it's winter time. When I say full blast I mean loud and proud. I even hear a high pitch whining sound that isn't the turbo. I've traded trucks for a day or two with friends who have the same powerstroke on two different occasions and their trucks are completely different animals. Never once heard their engine fans run hard and engine compartment was tons quieter than mine. My factory guages are running normal all the time and the truck never lacks power, and I never smell coolant or exhaust fumes. But my fuel economy is never above 15 mpg.
Last nite I was trying to figure out why my brake lights weren't working and found a tiny cable under the steering column not hooked up. It appears to hook to a tab that rotates when you put the truck in gear and has a threaded adjustment piece about 6 inches away and directly to the bottom of the console. What does this thing do?

 

I suggest taking your truck to another dealer, even if you have to drive. I have towed 13k-15k in 105 degree heat and my fan has never come on. I dont think i have ever heard it since owning the truck.


If its allways on, something is wrong. Sadly there are techs out there that instead of looking for a problem, they just read the computer and go on to there next ticket.

As for the cable, i dont know i would have to look when i get out to the truck.

 

I figured out what that little cable under the column is for, it calibrates the pointer for the shift selector.

 

Went to local shop today and put it on a scan tool. Got a code.

Code#- p0528 fan speed sensor circuit no signal

In my quest to find this problem I check a lot of connections and may have unplugged the fan at some point and replugged before turning the ignition ON so would that cause the code to show up?

Where is the fan speed sensor? Is there a relay? fuse?
Also checked the ECT sensor reading, was showing 0.6 volts at 190 degrees. That seems correct.

 

I second the new dealership. This should be a very easy fix.

 

Where are you located?
We have some of the best 6.0 techs in the contry on this board, you may be near one.

 

Gentlemen,
I cringed while reading this post, not because the problems are horribly expensive or hard to fix, but because of the shabby treatment you received from the dealership. Customer Service was one area where Ford always kicked GM's but.

My sister drove a Buick for years, then traded for a Crown Vic. The dealership always left a chocolate mint on the seat after maintenance and the car was always freshly washed -that never happened at G.M. To make a long story short, her driveway is now full of Ford vehicles.

 

I'm located near Crawfordsville, Indiana.

I spoke to a different dealership today and they want to start by reflashing, then see what happens. My last flash was a year ago. This particular dealer is supposed to be MUCH better with diesels than most and they are not overwhelmingly expensive, they said the flash would cost $35.

 

Also they said the programmer could be causing problems but I know the problem still exists with the stock program. I use a Sniper interface. I spoke with my salesman and he said that the Sniper won't change the parameters of the engine fan and shouldn't affect it in any way.

 

Just an update. Today was slow around the farm and curiosity got the better of me so I went back to my local mechanic and borrowed his scanner and Shopkey computer and started testing. Still throwing same code. Monitored the scanner while driving... ECT 192 degrees jumps to only 194 when accelerating then back to 192, EOT 192 degrees, all the while fan runs hard while accelerating whether the AC is on or off. Ran the test that goes- push the brake pedal, press and release E-brake, cycle O/D, cycle 4WD, push all the cruise buttons, turn the wheel....etc. Then I finally notice it isn't reading any fan rpm's, so I check the fan and its running. Drag the scan tool to the front and begin wiggling wires and I think I found the culprit. The fan harness plugs together at the top of the fan shroud and to the left. The white wire between that connection and the fan clutch when moved allows the scanner to read fan rpm's. That connection is fastened to a plastic piece on the shroud and for some reason will pull straight back about 4 inches and then contacts the fan blades. At some point this has made hard contact so tomorrow the fan assembly is coming out at we'll those wires an ohms test!
I was really excited to find this problem, I've been putting up with this condition for 20 months now all the while Etter Ford's Tech tells me that it's normal operation.

 

Fixed!!! The orange wire was broken.

 

This is why I go to this site. Congratualations on the fix and shame on your dealer tech. rc

 

Do the 05's have an electric fan? I have an 04 with a fan clutch that is making a rattling noise at idle that has been bugging me for a couple of years. Have ya'll ever heard of that happening to 6.0?

 

my 03 has a rattle that i can hear when standing outside the vehicle, i never knew or cared what it was, but now with your post i'm guessing mine is the same thing

 

umm you have an 05 and you paid to get a reflash? why? its a warrenty concern ford pays for that! you are getting ripped off and need to become the pissed off lawsuit ready customer when you go in next time, especially since they supposedly checked it out and said nothing was wrong and you found the busted wire, the very least a refund is in order. if they got the 528 the pinpoint test for that code involves ohming those wires, RIPPED OFF!!!!