I am sorry that my first post is a question and not an answer to a problem. I have a 04 Super Duty with a 6.0. It is an 9/03 build. I purchased the truck with 127,000 miles and currently have 158,000 miles.
It was relatively trouble free until 154,000 miles. At that time I had a no-start situation and after trying everything I read here, I took it to a shop. the discovered a HPOP and other problems. I believe they changed the ICP, Irp and other PC or similar sensor problems. $2,500.00 later the truck was running and all as right with the world.
Fast forward to Saturday and I had a real hard start. Since it was due for a oil change and a fuel filter change, I waited until Sunday to do it. I changed the oil and filter and the fuel filter and then spent the next 3 hours trying to get the truck to start.
It started but sounded like an old F&M motor until it warmed up. After starting and warming up, it ran fine and started up great. I was told it was the glow plug controller so I changed it out.
The change out does not seem to be a fix. I hope someone here can give me a place to go and either cry or find a fix.
What do I need to look at next? Thanks in advance. Don

 

How did the truck run before it had warmed up? A lot of times problems that seem to go away once warm tend to point towards injector problems. Were there any other symptoms?

 

The truck ran fine before the problem started. It runs fine after I get it started. I put over 150 miles on it after I get it started. It just is a pain to start in the mornings. I hope this helps. Don

 

Welcome to FTE!

Check the FICM voltages. There is a thread on it in trhe Tech Folder.

 

I Will check them again. The last check was 48 volts across the board. Don

 

When was the last time you had a flash update to the processors? What oil do you use?

 

I have had the truck for two years and no flash. I use 15/40 Rotella. Don

 

To me it sounds like injector issues - most likely Stiction. I definitely recommend 5W40 and the most recent flash for minimizing Stiction issues. Problem is that after awhile, Stiction is irreversible and new injectors are required.

Stiction (or oil latching):
There is a small spool valve in the top of the injector that controls the flow of high oil pressure fed to the intensifier piston in the fuel injector. That spool valve only moves .017", back and forth, on and off every time the injector fires. Many factors play in to how well that valve works such as, oil temp, oil quality, normal wear, ambient temp, and many others. As this valve ages it polishes itself inside the bore of the spool valve and as the spool valve slams back and forth it can set up the condition like a suction cup, hanging the valve to one side or the other. This uncommanded uncontrollable condition is called stiction. Mostly its a rough run cold condition but in severe cases it can be a no start or pretty harsh misfire condition. Oil that stays inside the valve on a hot engine shutdown and is allowed to cool slowly in the injector can aggravate the condition on restart, so the newest reflash uses inductive heat after shutdown to keep the oil warm, keep its viscosity low, and maximize the oil flowability to purge the oil from them. It has worked fantastic. It is an excellent preventative measure.

 

I sent the truck to the shop. The found about four codes and none seemed to fix the problem. They re-flashed the FICM. After two weeks and no solution, they "decided" that the oil was dirty so they changed the oil, filter and both fuel filters and called to tell me it was fixed.
I explained to them that the oil was changed at the first hard start along with the fuel filters. They still claimed that it was fixed. I took the truck home and the next day, it was back as before, hard start.
I plug the truck in every night and it will start with minimal effort. If I leave it unplugged, it is very hard to start.

That is where I am at now. I guess I will have to see if "sticktion" is my problem. Thanks for the help. Anymore suggestions will be appreciated. Don

 

don so if I read right the truck starts fine pluged in?
you can have a few things that will cause this.
ficm voltage as stated.
injectors going bad.
low compression issue
excessive blow by see compression issues.
failed glowplugs but most likly not unless its winter were you live.
I tend to think its going to be injector related.

 

Yes, it starts fairly fine when it is plugged in. It runs fine after it is started. I tested the FICM voltage a month ago and it was 48. There is no blow by. I tend to believe it is what you suggested as an injector problem.
I have worked on diesels most of my fifty years but this is not your daddy's diesel! Don

 

working on this engine is like taking candy from a baby.....maybe chuck norris's baby... but a baby none the less.

 

Today I had a real strange situation. I went to start my truck and it would just crank. It did not even try to run. I checked the fuel filter to see if it was getting fuel and it was. Still no start after numerous cranks.
After about two hours, I decided to check the fuel again. Still plenty of fuel and it filled the filter housing fast. I grabbed the wire harness and pulled on it to check for loose connections but found none. I then tried to start the truck again and it started almost immediately.
What did I do? Bad wire harness? Got air out of fuel line? Don