2004 6.0L issues. Please help!
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Senior User
Joined: Sep 2007
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From: Tampa, FL.
2004 6.0L issues. Please help!
2004 Ford F-250 SuperDuty 6.0L Diesel.
So my truck has been sitting for a couple weeks because I was on vacation. I came back and have been driving her for about 3-4 days now. Tonight on my way home OUT OF NO WHERE; My truck has absolutely no power. I couldn't get over 50-60mph with the pedal to the floor, and when I was slow down for idle it would bog down and barely chug to stay alive. I would honestly say I have maybe 80% power loss. When I got home I turned off the truck, waited a few seconds and tried turning the truck back on and it wouldn't turn on at all. It would turn over but it couldn't roll over and start.
I am going to assume it's my injectors but that would suck horribly if they went out because I know they are very expensive.
If you guys need to know any more symptoms of what the truck is doing I'll answer as soon as possible for that I am trying to figure out what this problem is.
All of you help is greatly appreciated!!
So my truck has been sitting for a couple weeks because I was on vacation. I came back and have been driving her for about 3-4 days now. Tonight on my way home OUT OF NO WHERE; My truck has absolutely no power. I couldn't get over 50-60mph with the pedal to the floor, and when I was slow down for idle it would bog down and barely chug to stay alive. I would honestly say I have maybe 80% power loss. When I got home I turned off the truck, waited a few seconds and tried turning the truck back on and it wouldn't turn on at all. It would turn over but it couldn't roll over and start.
I am going to assume it's my injectors but that would suck horribly if they went out because I know they are very expensive.
If you guys need to know any more symptoms of what the truck is doing I'll answer as soon as possible for that I am trying to figure out what this problem is.
All of you help is greatly appreciated!!
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Senior User
Joined: Sep 2007
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From: Tampa, FL.
I just went outside to start my truck 2 minutes ago after leaving it overnight. She started right up, but white smoke came out of the exhaust on the initial start up. [Which is normal] the only abnormal thing is that there is a continuous light amount coming out still. Usually it stops right after the start up.
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Senior User
Joined: Sep 2007
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From: Tampa, FL.
I don't believe I heard a "whoosh" noise. It just felt like if I were to give it any throttle at all I would can zero power. It just feels like the truck has absolutely no power when I drove it last night. The max mph I could reach was like 53mph, and that was with the pedal to the floor gaining no mph after that. It felt like my truck was shaking once I hit a certain MPH/RPM.
FTE Leadership Emeritus
Joined: Aug 2007
Posts: 42,085
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From: Lakewood, Ca.
I'm no tech or anything close to it, but I think a good place to start would be to check the rubber boots between the intercooler and the turbo to be sure they are not blown off or torn. Can't hurt -
FTE Leadership Emeritus
Joined: Aug 2007
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From: Lakewood, Ca.
Here's a link from the tech folder on fuel filter replacement - It's real straight forward.
FUEL/WATER SEPARATOR DRAIN PROCEDURE
FUEL/WATER SEPARATOR DRAIN PROCEDURE
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Laughing Gas
Joined: May 2005
Posts: 1,082
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From: Illinois
How many miles are on the truck? When was the last time you changed the fuel filters? Have you every replaced or cleaned the EGR valve?
I have experienced the same condition when my fuel filters get plugged (usually from bad fuel). I also experienced this condition when my EGR valve was full of soot. I had this happen at around 74,000 miles. I pulled the valve, carefully cleaned it off (as per the instructions in the tech folder on this site), and everything is running normal for me.
I have experienced the same condition when my fuel filters get plugged (usually from bad fuel). I also experienced this condition when my EGR valve was full of soot. I had this happen at around 74,000 miles. I pulled the valve, carefully cleaned it off (as per the instructions in the tech folder on this site), and everything is running normal for me.
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Brett Foote
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From: Sarasota, fl
How many miles are on the truck? When was the last time you changed the fuel filters? Have you every replaced or cleaned the EGR valve?
I have experienced the same condition when my fuel filters get plugged (usually from bad fuel). I also experienced this condition when my EGR valve was full of soot. I had this happen at around 74,000 miles. I pulled the valve, carefully cleaned it off (as per the instructions in the tech folder on this site), and everything is running normal for me.
I have experienced the same condition when my fuel filters get plugged (usually from bad fuel). I also experienced this condition when my EGR valve was full of soot. I had this happen at around 74,000 miles. I pulled the valve, carefully cleaned it off (as per the instructions in the tech folder on this site), and everything is running normal for me.
Senior User
Joined: Jan 2008
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here is a simple route to try first: if you have a scanner try and pull some codes from the ecm, check both fuel filters to see if anything is wrong there, check egr valve by disconnecting it, and see if this helps anything or pull the valve and see if it is stuck, usually if you see white smoke stuff coming out the exhaust pipe it may be the egr cooler is leaking, busted or a possible head gasket issue that is causing this symptom, also check all intake boots (the blue boots on the pipes connected to the turbo) also if your engine is chugging of turbo farting it can be from the turbo vaines sticking causing a lack of power, but you will need a dealer to possibly check this for you, also one or a few of the injectors or hpop components may have problems, is the truck hard to start when cold/hot? any black smoke on start up/acceleration? any check engine lights coming on?
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if its the fuel filters, change them and run a good fuel system cleaner through the system like standyne or powerservice, etc. after this take it back out on the road and drive it hard if possible to see if the situation is fixed.
Cargo Master
Joined: Mar 2007
Posts: 3,103
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From: AB/BC
White Smoke, Lack of Power, Exhaust Odor, Surge, Runs Rough, or No Start:
The above symptoms on trucks equiped with the 6.0 when the engine is cold may indicate a sticking injector spool valve. To reduce the likelyhood of this condition, there is a revised program available for the Fuel Injection Control Module. This new program uses the injector spool valve solenoids to preheat the oil at the injectors. The diagnostic computer has to be at version 47.8 or higher, or 48.2 or higher to upload this new program. The new program supercedes TSB #06-2-13, which caused the injectors to actuate (buzz) for 30 seconds after the engine is shut off. With this program the injectors will no longer buzz on shut-down.
TSB #07-5-4
This supercedes TSB 06-2-13, which advises the above conditions may be related to poor oil maintenance practices. However, the programming mentioned in the current bulletin does not obviate the need to perform oil changes at the recommended intervals.
The above symptoms on trucks equiped with the 6.0 when the engine is cold may indicate a sticking injector spool valve. To reduce the likelyhood of this condition, there is a revised program available for the Fuel Injection Control Module. This new program uses the injector spool valve solenoids to preheat the oil at the injectors. The diagnostic computer has to be at version 47.8 or higher, or 48.2 or higher to upload this new program. The new program supercedes TSB #06-2-13, which caused the injectors to actuate (buzz) for 30 seconds after the engine is shut off. With this program the injectors will no longer buzz on shut-down.
TSB #07-5-4
This supercedes TSB 06-2-13, which advises the above conditions may be related to poor oil maintenance practices. However, the programming mentioned in the current bulletin does not obviate the need to perform oil changes at the recommended intervals.
Cargo Master
Joined: Mar 2007
Posts: 3,103
Likes: 32
From: AB/BC
These are some problems that a bad ICP cause but the TSB was on a earlier build.A bad ICP will cause these symptoms on any 6.0L. ICP Sensor Problems:
This is now covered by Customer Satisfaction Program 03B05. It applies to trucks build through 2-3-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.
Some 6.0 PowerStroke engines may exhibit rough/rolling idle, poor idle return, lack of power, injector fault codes or excessive smoke. This may be caused by the ICP sensor reading incorrectly. The ICP sensor and connector terminals should be inspected for damage (the ICP is at the rear of the engine, under the turbo), and the sensor circuits checked for opens or shorts. With the engine at operating temperature (engne oil above 180 degrees), the ICP sensor signal should be 0.16-0.28 volts (less than 70 PSI) with the key on and engine off. The engine needs to be off for at least two minutes for this test. If the ICP signal is not within this range, replace the sensor with P/N 3C3Z-9F838-EA.
This is now covered by Customer Satisfaction Program 03B05. It applies to trucks build through 2-3-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.
Some 6.0 PowerStroke engines may exhibit rough/rolling idle, poor idle return, lack of power, injector fault codes or excessive smoke. This may be caused by the ICP sensor reading incorrectly. The ICP sensor and connector terminals should be inspected for damage (the ICP is at the rear of the engine, under the turbo), and the sensor circuits checked for opens or shorts. With the engine at operating temperature (engne oil above 180 degrees), the ICP sensor signal should be 0.16-0.28 volts (less than 70 PSI) with the key on and engine off. The engine needs to be off for at least two minutes for this test. If the ICP signal is not within this range, replace the sensor with P/N 3C3Z-9F838-EA.
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