Starts, Idles Rough, Zero Power
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Starts, Idles Rough, Zero Power
2004 Excursion, 108K miles. Headed to work, pull up to stop light, starts running rough and does not have enough power to do anything more than slowly roll through the intersection. Proceed to tow it to the dealer that did extensive (turbos, wiring, EGR, ECM, etc) warranty work hoping that something might be covered under prior work warranty. Ford says both batteries are putting out low amps (replaced approx. 2 years ago), FICM, 2 injectors, and the fuel pressure regulator are bad (none of these done before) and they will gladly repair for just over $3K. 
Sorry, warranty expired at 100K miles (knew that, but was hopeful).
Any thoughts on my predicament before I have it towed to a recommended independent diesel shop? Thanks!!
Sorry, warranty expired at 100K miles (knew that, but was hopeful). Any thoughts on my predicament before I have it towed to a recommended independent diesel shop? Thanks!!
Lead Driver
Joined: Jan 2005
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From: Huntington Indiana
These engines are very sensitive to fuel quality,pressure, flow etc. I wonder if you got some very bad fuel and the filter is plugged (as a easy fix) . I had this happen and they found the wiring harness on the engine was shorted. This was under warranty thank goodness as it took the teck 16 hrs to replace.
Good luck and since you are paying the tab a second opinion is called for.
Look in the TSB listing under full text tsb for the following TSB 04-9-3 also look at TSB 06-13-3 look at erractic high pressure oil supply section
Good luck and since you are paying the tab a second opinion is called for.
Look in the TSB listing under full text tsb for the following TSB 04-9-3 also look at TSB 06-13-3 look at erractic high pressure oil supply section
FTE Leadership Emeritus
Joined: Sep 2003
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From: Houston, Texas
You may not have to spend $3K...
Start by getting some new batteries, changing the fuel filters, and testing the FICM and alternator if it still doesn't start.
You're basically killing a number of birds with a few stones...
Start by getting some new batteries, changing the fuel filters, and testing the FICM and alternator if it still doesn't start.
You're basically killing a number of birds with a few stones...
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No, was at about a half a tank. But the other thing that I couldn't figure out was that the check engine light did not come on. Is that normal when FICM's and injectors fail? The only code that was stored indicated a glow plug issue. Of course I can't remember the code but when I researched the number it was a glow plug. Anyway related? Thanks again.
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Resident smarta$$
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From: Oaks,PA
Was there ever a solution for the OP? TOW4H2O, did you get it fixed, and if so what was the issue(s)?
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Laughing Gas
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From: Illinois
You'll get the exact same symptoms with a dirty EGR valve. The same thing happened to me a couple of years ago. Truck ran fine, stopped at a traffic light, pushed down on the accelerator and absolutely no power. I barely made the turn and got to the side of the road. I unplugged the EGR valve and was able to drive home, but couldn't get over 20 psi of boost. I did thorough cleaning of the EGR valve, put it back in, everything runs great. I now clean the EGR valve every six months or so as part of my maintenance routine.
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4 weeks later
Sorry, meant to give an update. Ford had it for almost 3 weeks "trying" to see if Ford would help out on the cost since most of the parts they wanted to replace had been done under warranty about a year and 25K miles ago. At 108K miles now it is out of warranty. Ultimately told I was on my own so I went and towed it to an independent diesel shop.
3 bad fuel injectors and 2 questionable fuel injectors was the diagnosis. Replaced those and runs like the old global warmer I have come to love. Ford had me down for 2 new batteries, a new FICM, new fuel pressure regulator, 1 injector and a couple other things I can't remember at this point so it was clear they were just throwing parts at it at my expense. When it is warranty work they can throw the kitchen sink in too if they want. Who knows what the final cost to me would have been if they replaced all their recommended parts in addition to all the injectors.
Happy 3 day weekend to those so lucky!!
3 bad fuel injectors and 2 questionable fuel injectors was the diagnosis. Replaced those and runs like the old global warmer I have come to love. Ford had me down for 2 new batteries, a new FICM, new fuel pressure regulator, 1 injector and a couple other things I can't remember at this point so it was clear they were just throwing parts at it at my expense. When it is warranty work they can throw the kitchen sink in too if they want. Who knows what the final cost to me would have been if they replaced all their recommended parts in addition to all the injectors.
Happy 3 day weekend to those so lucky!!
Fleet Mechanic
Joined: Jun 2006
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Sorry, meant to give an update. Ford had it for almost 3 weeks "trying" to see if Ford would help out on the cost since most of the parts they wanted to replace had been done under warranty about a year and 25K miles ago. At 108K miles now it is out of warranty. Ultimately told I was on my own so I went and towed it to an independent diesel shop.
3 bad fuel injectors and 2 questionable fuel injectors was the diagnosis. Replaced those and runs like the old global warmer I have come to love. Ford had me down for 2 new batteries, a new FICM, new fuel pressure regulator, 1 injector and a couple other things I can't remember at this point so it was clear they were just throwing parts at it at my expense. When it is warranty work they can throw the kitchen sink in too if they want. Who knows what the final cost to me would have been if they replaced all their recommended parts in addition to all the injectors.
Happy 3 day weekend to those so lucky!!
3 bad fuel injectors and 2 questionable fuel injectors was the diagnosis. Replaced those and runs like the old global warmer I have come to love. Ford had me down for 2 new batteries, a new FICM, new fuel pressure regulator, 1 injector and a couple other things I can't remember at this point so it was clear they were just throwing parts at it at my expense. When it is warranty work they can throw the kitchen sink in too if they want. Who knows what the final cost to me would have been if they replaced all their recommended parts in addition to all the injectors.
Happy 3 day weekend to those so lucky!!
If not could you find out and let us know.
DSMMH
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They did not give me a definitive answer other than it could have been something made it past the filters or it was just their time to go. The 3 bad ones were allowing the cylinder compression to push the fuel backwards through the fuel system. Made it so that on day of failure it was running on maybe 3 cylinders.
Fleet Owner
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Stiction is a very common reason for some of these symptoms. For that, the newest flash and 5W40 oil is helpful.
As far as failed injectors go, the top killer of injectors is low fuel pressure. After the coolant filter, a fuel pressure gauge is the top thing to spend $$'s on. Especially if you have already experienced some injector failures.
As far as failed injectors go, the top killer of injectors is low fuel pressure. After the coolant filter, a fuel pressure gauge is the top thing to spend $$'s on. Especially if you have already experienced some injector failures.
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Why would you ask about the fill up? The reason I ask is that this exact same thing happened to me, and it was right at about 100 miles after a fill up. Ive replaced the fuel pump, filters, checked sensors, and searched and searched the internet for ideas. Do you think it could just be bad fuel?
Lead Driver
Joined: Jan 2005
Posts: 7,782
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From: Huntington Indiana
Why would you ask about the fill up? The reason I ask is that this exact same thing happened to me, and it was right at about 100 miles after a fill up. Ive replaced the fuel pump, filters, checked sensors, and searched and searched the internet for ideas. Do you think it could just be bad fuel?