I have a long story, I'll try to keep it short, 2001, 7.3, 125,000 miles. I've own it for two years and 50,000 miles. I love it and don't want to sell it, but I can't get it fixed. The problem first showed up under heavy load at hwy speeds about 6 months ago. I tow a trailer with it, about 7000 lbs. It would start to shake and lose power on the hwy and got worst when accelerating. It finally stopped pulling altogether and I broke down while returning home from vacation.
I left the truck at a Ford dealer in Ga. and asked them to fix it. They had it for 3 weeks and told me three different times that it was fixed.
The first week they replaced the ICP sensor, codes P0476,P0603,P0605, & P1211. That did not fix the problem.
The second week they installed F81Z 6C673 BA Solenoid Asy. They also installed 2 injectors that they said failed. They changed the oil saying that it looked thin. I had the oil changed before I went on vacation and used the right oil. This did not fix the problem.
The third week they installed CM 5013 Regulator- Fuel Pressure.
Installed Pump Asy, High pressure pump. They also replaced two more injectors. This did not fix the problem.
I picked the truck up in Ga. and drove home about 300 miles. I broke down 6 times and had to pull over and let it sit for about 1/2 hour and start up again. I made it home and took it to my mechanic. My mechanic replaced the turbo pedestal and I drove the truck for about 3 days and it ran like new, then I started having, what seemed to me to be a different problem. Under heavy acceleration it would blow blue smoke and not make much power and then it would run worst and would just idle, I had to limp it back to the shop. It has always idled find. I have changed the oil on schuded along with the fuel filter, the air cleaner is fine. I was running Bully dog program, but it has been removed while trying to find the problem. At this point just about every sensor has been replaced. I dropped the fuel tank to check for any problems and did not find any dirt. I think that is everything, I'm no expert and I need some advice, Please help.

Ford lover

 

Have you checked the under valve cover harness coneectors? They are notorious for coming loose, resulting in rough running, idle, and bad injector symptoms. Search this forum for "UVCH" and you'll get pics and such. Easy fis if this it the problem. You should also take close look at the wiring harness that is secured on bracket above the drive side valve cover. Look for chaffed wires from rubbing on the valve cover.

 

Maybe the turbo's shot, thats the only thing that comes to mind. Subscribing.

 

i would have to say the UVCH. that would be the next thing i would check. A buzz test would test the UVCH right?

 

Did you check the screens inside the fuel pickup assembly?
They are notorious for clogging up, creating fuel starvation problems and the symptoms of that exactly parallel the problems you are describing.
Down to the blue smoke. That is caused by airated fuel in the fuel rail because the injectors have used up all the available fuel and the fuel pump cannot keep up because the pickup strainer is clogged.
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Everything you are describing makes me think low fuel pressure, especially the breaking down while under load. Fuel demand is greatest at that point in time and the engine just falls flat on it's face because it's running out of fuel..
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I think you've spent a lot of unnecessary $$$ up to this point, sorry to say.

 

Looks like you have some great leads to follow.
Could the blue smoke also be from a poor injector install? Mabye scuffed an o-ring so it's leaking oil by?
I think Dan is onto the problem though, check the pickup screen for clogging. We've had that problem when traveling down the highway. Limped it along for a while, eventually took the fuel line going to the pump off, blew into it attempting to unclog the screen, put it back together and were up and running like normal. It was interested how it happened all of a sudden, figured it'd be more gradual.

Keep us up to date of what you find. These guys will have your problems fixed and save you all sorts of money. Sad thing is most of these guys know more about these trucks than the dealerships working on them.
Hope you get it fixed!

 

Thanks for the advice, All these things could be the problem, the bad thing is the dealer did cut an O-ring on one of the injectors and had to do it over. I wonder if they cut more then one? I will have may mechanic check all these things. This form is great. I need my truck. Where is the screen for the fuel located? We did drop the fuel tank and check for obstructions.
Wires were the next place that we were going to look at. My mechainc has said that it could be some wire somewhere that is rubbed bare and causing a problem. That has got to be hard to find. I'm about to tell him to replace the whole wire harness. Do you think that would be a good idea?
Turbo? Do they go bad a little at a time? I would think if they go bad it would happen fast. Like I said I'm no expert, I just thought a turbo would self destruct when they go bad?
What is a buzz test? My mechainc does hook up something when checking and he said it keeps coming back with a code 1211.
The fuel presure checks out Ok, but what fuel volume? Is there a differance and a way to check volume?

Thanks again, Diesel forever............

 

I'd just like to clarify what Dan is saying here. He is referring to the 2 cylinder shaped screens inside the white plastic thing (mixing chamber) on the fuel pick up assembly inside the tank. He is not referring to the wire mesh thing on the bottom of the pick up foot, since that will typically become unplugged by itself. The screens in the mixing chamber look like this



Your description has me thinking fuel restriction also. Paying a mechanic to change your oil for this problem only because "it looked thin" is unfortunate.

If you drop your tank again and take apart the white thing on the fuel pick up, I'd guess the screens in there are clogged up similar to the picture above. The way to keep this from happening again, is just to throw that thing in the trash, add an inline filter between the tank and the pump, and do a couple of other things while you're in there. Here's a link on how to do the in tank mods. http://www.guzzle7pt3.com/hutch.php

 

Thanks F350-6, this form is great, I will check fuel screen first thing Monday and let you know if it fixed the problem.

 

Just keep these guys up to date and they will work through ANYTHING with you.

 

I'm pretty sure you are going to come back and report that, that was the problem.
Classic symptoms..
BTW, this was my cure for that problem.
And MAN what a difference!!!!!!!!!

 

just want to follow this to learn what was wrong, hope you get it fixed lots of good info here to check..

 

I would go with what Dan said on this one.

 

Caveman: Are you having any luck or have you traded for a Dodge?
Please keep us posted if this fixed it. It may come in handy for helping someone else. Thanks!
charlie

 

subscribing.... i was told by a friend that there was no filters/screens in the tank, can you replace them or do have to replace the whole thing?

find out anything yet caveman?