Happy Easter BamaDiesel. Whereabouts are you? I hope that yesterday was productive and maybe the problem was solved, but if not, and we're close, then I would be happy to lend a hand. I am in central Alabama (Montgomery), I will be with the family today for Easter activities, but will be around most of next week. my phone no is 3344621688, call me if I can help.

 

Thanks! and Happy easter to you and your family too!

I'm In Tuscaloosa, I have area calling, So I may give you a ring tommorrow, And thanks again!

And an update, i'm going to do the fuel pump/lines mod today maybe that'll help some, I'll post some of the pictures of the fuel lines later, you'd not believe at the black scale inside the metal lines!
Its a wonder the truck ran at all!

 

While you are cleaning things, there is aan internal screen in the upstream end of the fuel pump, and it also has an internal checkvalve so you can't just backflush it. You might try an aerosol can of brake cleaner in the upstream end of the pump to try to flush it out.

 

Time for an update, sorry its taken so long every things been real busy the last week or so.
Ok, I did find out that the injectors DID come from Pensacola fuel injectors.
i've did some research, and now i'm not so confident about the injectors.

Here is an update on what's been done so far, and how the truck is running.

Dropped the fuel tank, which was actually very clean inside, BUT all of the fuel lines had the same black scale inside them that was in the fuel filter bowl.
The metal lines I removed, vat cleaned, the rubber lines I replaced.
I added some more oil in case it is a cracked pickup tube. (tried not to use too much)

and as you know the IPR, CPS,ICP, BPS and tube have all been replaced, fresh oil & filter, ohms check good on the 9 pins.

The truck shows no codes at all, And my Cornwell scan tool does pull enhanced codes for the ford diesels. (at least we got rid of all the codes)

Cold start, truck runs fine, after a few minutes it starts running rough, (no smoke at all unless you try to rev it up, then just small puffs of bluish black smoke) almost seeming to be missing, to the point that it will not hardly pull itself at all, Died twice on last test run yesterday (first time its done that) before you could drive it about 30 miles before it starts, now it starts within 2.
You can try to hold it to WOT, but the RPM's will only go to about 1 to 1.2
If you pull over and let it idle for a minute the truck runs perfectly fine for a minute or two, if you shut it off, and turn the switch on, wait till the pump stops, do it again (maybe its just the time it takes to do that) the truck runs fine also. Letting it sit with the engine off for about 10 mins also seems to work.
I have a couple of questions, Since i'm not specialized on ford trucks, (but i'm learning a LOT lately) What are the signs of the HPOP going out, and the fuel pump going out? I was wondering if maybe the truck was starving for fuel after a few minutes of running, then upon idle the fuel had a chance to "catch up"? Any suggestions appreciated!

One side note, As I was typing this, I got a call about another ford, starting to miss bad, but this one is smoking traveling at normal highway speed.
They stopped and had the codes pulled at an autozone (yay) no codes showing on that one also.

As you can tell, I guess i'll be learning more and more about fords!

 

Anyone? =)

 

If I recall corrrectly, the fuel port fittings on the heads (one on each head) have internal screens as well. It could be that they are partially plugged from the same goo you found inside your fuel bowl. You should be able to pull the fittings, soak them well, and blow them out with compressed air. Worst case, you can also drill them out as long as you know that you'll keep your main filter element in good shape, but I would try to clean them withOUT coring them first.

Someone posted pics of these little buggers a couple years ago, but I can't find the thread right now. Perhaps someone else will find the link.

 

Possibly a bad fuel pump, but dont replace it until you check it. How many miles has it been driven since the IPR was changed? Anytime you open up the HPO system and air gets in it, it can take a while to get out.

The HPOP is nothing more than a geardriven axial piston pump, While not rare to lose some performance, very few actully go belly up. The pump must maintain at least 500PSI to even fire the injectors at start up. The dead miss makes me think that it is either an injector, or the IDM. Either the IDM cannot make enough voltage to keep an injector happy, or the injector coil itself has gone bad.

 

This whole description makes me think that, indeed, the engine is starving for fuel. Do you have a fuel pressure gauge handy that you can connect to the fuel rail temporarily? It's 1/8 NPT thread and the handiest spot is the port where it comes out below the AC pump.
You mentioned that you dropped the tank, did you take apart the mixing chamber and clean out the screens?
Also, with the mention of all that black goo on the inside of the fuel lines, here is something to remember: There is a screen on the inside of the inlet of the fuel pump that will quickly get clogged with debris and you cannot clean it out very well. There is a check valve on the inside of the outlet of the fuel pump that prevents any sort of back flushing.

 

And I'm not trying to sound like a hard nose, but until a fuel pressure reading is taken, any other diagnosis is going to be useless in this thread.
The test must be taken with the engine under load, not at an idle when it is running OK.

 

An update, Jonathan(Bamadiesel) called me yesterday and we trouble shot over the phone. We talked about his fuel pump, and he turned the key and I listened to it over the phone, Its pretty much shot. itermitent buzzing from pump, straining one second , free running the next.
I am meeting him half way between his place and mine on Thursday and giving him my old fuel pump to try. Hopefully it will save the man a few $$$ and get him ack up and running

 

Ahh, yes, the "mad bee" sound.
Thanks for the update.

 

Just a note on this. Autozone cannot pull codes off of Powerstrokes. Their scanners are not compatible.


Brandon, that was a very nice offer to give him your fuel pump. Reps your way if the po-po don't get me.

 

Reps to ya Brandon. Hope that gets Bama up and runnin.

 

Well, I called and told Johnathan that I would be in Maplesville (about 1/2 way between his house and mine) at 10:30 this morning and would meet him at the Triple G Truck Stop(one of my customers). I waited from 10:00 till 12:15 and didn't ever see him. I called the number he had given me a couple of times, but it was his home phone, and I got the answering machine. Hopefully he will call me soon and I can get him this pump, so he can get that truck up and running.

Johnathan, Call me, If I dont answer, leave me a message. I have a softball game tonight, so I wont be around the phone from 5pm till 8pm.

 

That sucks Brandon. He should have called you if he couldn't make it. Hope something didn't happen on the way to meet you.