Hello,

I have a few issues going on with a 7.3 in a 22 pickup. The issue has been present since new and has been to the dealer for repair many times, however they keep kicking the can down the road saying something needs to break first. I have outlined the way to replicate the issues, but they can’t seem to replicate it with a computer connected. Well, the first motor broke at 28k miles( currently at 30k). The new motor does the same thing and before I grenade that one too just after warranty I was hoping to find a resolution.

Issue#1

The issue most commonly occurs when the truck has sat for 6-10 hrs from a full thermal cycle when ambient air is below 50 degrees F. After turning the key the RPMs hang out about 1200 RPM. After about 20-30 seconds the engine bogs down to about 400 RPM, then surges to 1200, then bogs, then surges, repeatedly for about 20 seconds, then levels out about 1000 rpm.

Issue #2

When shifting into drive/reverse during the first three minutes the truck struggles not to stall.

Issue #3

Extended high idle times.

In the last few weeks the high idle times sometimes hang for about 4-5 min rather then dropping down to 1000/800 over about 45 seconds.

Has anyone seen issues like this and had a resolution?

I am suspect that the PCM is calling for extra fuel and flooding out certain cylinders and washing the cylinder walls. The first engine had significant cylinder wall scoring on the passenger bank and subsequent cam wear on those lobes only. The cam wear doesn’t appear to have pitting or delamination. I never had any DTCs, but found metal in the oil. Oil had been changed every 4-5k with penzoil ultra platinum. I am concerned that the cylinders are getting washed and scoring and so I don’t want to damage the new engine. I have been messing around looking for vacuum leaks but haven’t found one. One of the O2 sensors was providing the pcm faulty readings, but replacing that didn’t solve the issue. Once I get the truck back from the dealer (currently there for this and 6 other issues including transmission, AC, and bearing) when the dealer and ford tell me again that they can’t find an issue and that it’s normal, I am going to start testing some items. I will be looking at vacuum leaks, fuel trims( to see if the pcm is calling for more fuel), evap purge solenoid, maf sensor. Is there any where else that I should look?

Thanks for you help and experience

Dan