No start after fuel filter change
 

Hey All, OK so I have a 2004 F-250 changed out both fuel filters and now can't get it to run. It will start up and run for about a minute then stall out. I have cycled the key/pump numerous times with no luck. When I look into the fuel bowl when I engage the pump it looks like it's pushing more air rather than fuel. It seems to be burning the fuel in the bowl and then stalling out. When I take the bowl cap off after it stalls it's empty.

Make sure the fuel filter on the frame rail is snugged up all the way flush against the housing until it will not turn anymore. I had to use a cheater to get it to tighten all the way

It tightened up nice..no leaks/drips

Seems to be a quick and easy process for most.

And there were no running issues that caused you to do the filters in the 1st place, correct?

Is the pump running when the engine dies? (you should hear it) and also check to see if it is hot. I'm wondering if you have crud on your pick-up screen in the tank...

When and where did you last get fuel?

I recently acquired the truck. Apparently the fuel gauge is a bit off. I ran it pretty low, low enough to stall it out. Inched to the gas station. After that it seemed to idle a bit rough. I thought maybe I picked something up out of the tank so I decided to start with new filters.......yes the pump is running when it stalls....shell fuel station

Inching to the gas station was it running rough on little fuel and/or stalls and restarts too? The fuel pump could be damaged...

Decent size (volume) Shell station? As in they sell a fair amount of diesel for that area? I'm thinking if so you likely didn't get the problem with the new fuel, tho crud could still be stuck to the pick-up screen...

Yes it's a pretty busy station. Well ever since that low fuel stall it idles rough and also when the overdrive engages while traveling, when the rpms get below 1500 it also runs rough. So the pump could be damaged yet still try to pump fuel? I guess I just figured it either worked or it didn't. And if you could hear it then it was working?

Yes, before it totally fails it could still be trying to pump fuel, or there is crud on the pick-up and it can't get enough.

What is inconsistent with all this: is the low rpm problem but fine at higher rpm? I could understand that if we toasted an injector or 2 (which is possible, they don't like to run dry), but you are reporting an empty fuel bowl, so the HFCM is not getting enough from the tank, or not pumping enough to keep it running -- so that is the opposite of what I'd have expected as your pre-filter change running problems, where it would starve as rpms increased. You may have more than one thing going on here...

Did you use Motorcraft or Racor fuel filters? Was there much crud in the HFCM? Wondering if we could have got any between HFCM and upper fuel bowl...

Are you set up to read live data from your truck? There are readily available things like Scangauge II or Smart Phone apps like Torque or Dashboss and also laptop programs like Forscan. We should make sure your FICM and other readings are healthy....

Likely the pump(HFCM) will still try to pump just can't get the job done properly. You really need a way to check what the fuel pressure is so that means a trip to a shop if you don't have the means to do so. Do the blue spring upgrade either way, if it has not been done already, countless threads on the benefit of doing it and it's a cheap, pretty easy mod to perform. Be sure if you take in to a shop or dealer they know how to work on a 6.0....you will know when they listen to you with some interest when describing the issues and don't look at you like you have two heads. If they diagnose and tell you it's time for head gaskets, run like the wind and don't look back.
As for your rough running issue, depending on the health of your injectors you may have one or more that didn't like being starved for fuel, and now are voicing their displeasure. 6.0 injectors can be funny that way, as well as a real hatred for a FICM that is not providing ample power for the coils. Not saying this is the case for sure, just a possibility. Might still all be tied to a weak HFCM. Don't run the truck anymore than you absolutely need to at this point until you can pinpoint the problem.
One more thing, most folks will tell you don't run below a 1/4 tank in these trucks, gas or diesel, countless threads on this issue as well.

Well I just tried the fuel pump again sounds like it is working but if I watch the bowl it seems to be pumping nothing but air.

Fuel gauge is reading half full but I'm not totally sure that this is correct. The tank sounds empy to me when I knock on it. I'm gonna get some fuel and try that.

No luck there... Gauge now reads 3/4 and still pumping nothing but air.

That would be ironic -- I had the impression around post #5 of this thread (your other user id), that you had just filled it up and decided to start by changing fuel filters, as in: the tank was at a known, pretty full level.

Yes I'd make sure I knew you had fuel, and while some have been successful at fixing their level senders (Yahiko had a good write up on how he did his), others just replace the unit AND while you are there, do the "Harpoon" mod on the vent line in the tank. Either way if you get in the tank you'll see what is in there.

Hope it runs with fuel :p, then we can tackle what probably is a different issue...

Taking nothing for granted here: you added fuel to the tank, right? If so your pick-up is clogged or your pump is toast. What brand filters did you use? How much crap was in the HFCM when you pulled the lower filter?