Ford 6.0L Power Stroke Diesel :: 2004 - Code P2284 After Oil Cooler Work?

I have the later model 2004 F250 6.0 (built May 2004). I have owned it since new. It has 157K miles.

My newest problem comes after I did oil cooler work. I know everyone points to the IPR and/or ICP, but my readings seem strange to me.

About three weeks ago I replaced the oil cooler with a Bulletproof remote unit that uses the factory oil cooler. During the job I removed and installed a new Ford IPR sensor and added the improved screen to it. I removed and installed new Ford water/oil temp sensors, a Ford low oil pressure sensor, and a Ford ICP sensor (in the pax valve cover). I also installed the improved turbo feed line and turbo drain tube. I rebuilt the oil filter/fuel housing and installed new o-rings and the blue spring. I have the dual alternator set-up and had been running the lower alternator unplugged for the last several years. (I know I know). So I swapped in a reman alternator.

I managed start-up after running batteries dead a few times. During the drive I felt idle speed jump up by itself a few times while at low RPM. I felt an unusual skip or two in the motor but the power seemed ok. I accelerated and the truck pulled fine. At highway speed I heard what sounded like the engine hitting a high rev and trying to cut out, but it was very mild. I noticed this first at 2000rpm, but it may have not been pronounced enough for me to notice it at lower RPM. When the cut-out occurred strongest I slammed the throttle down to see if the problem would worsen, but the truck accelerated well with no cut-out, but when I eased off the throttle at higher RPM the cutting out returned. My Banks IQ showed P2284.

I installed 2 new batteries and replaced the ICP pigtail and soldiered it. That had no effect. I put the old ICP sensor back in. That had no effect. I borrowed a Snap-on Solus Edge scanner to test the truck. I would add that the truck starts up as quick as it has always started; 3-5 seconds.

Scanner results:
Key-on, engine off, ICP (voltage) reads .25, IPR reads 15.

During the crank sequence (before engine start), on a freeze frame, RPM is 157, ICP(voltage) reads 1.04, IPR reads 21, ICP pressure reads 768.8 psi. That seemed kinda normal.

Engine running at idle RPM, I read ICP (voltage) 1.2, IPR 15, ICP pressure 863.1psi. That seemed okay.

I drove the truck with a cleared code and noted that something occurred to change my readings. Before the change while driving under a short heavy acceleration to 54mph, I noted these readings: 3533rpm, ICP (voltage) 3.77, IPR 60, ICP pressure 3400.1. I eased off the throttle, stopped the truck, and noted an uncommanded REV-up by a few hundred RPM and back to idle. It was a quick burp. Afterwards ICP pressure and IPR readings went strange and the code 2284 came up. Looking at the graphs over time, RPM, ICP pressure, ICP voltage, and IPR all follow a similar curve---until the REV-up occurred.

The scanner next showed that as I mildly accelerated to 1705 RPM (about 15mph) graphs showed ICP voltage, ICP pressure, and IPR went up. But when I let off the throttle ICP pressure became fixed at 869.9. I continued to drive the truck.

The truck accelerated fine as it had under previous runs. The Scanner shows that although ICP pressure remains fixed, the ICP voltage climbs and falls with RPM. With RPM ranging from 630 to 1800, IPR holds at about 30. Then under a very heavy acceleration to 44mph, ICP pressure began to increase above 869.9, then followed ICP voltage upwards. ICP pressure climbed to 3479psi with an ICP voltage of 4.64. At that moment IPR read 69%. That seemed normal until I let off the throttle. Then ICP pressure drops back to exactly 869.9 which I assume is some sort of PCM-induced value.

It is during this time at higher RPMs I can hear the engine-cut-outs, but they are mild and the engine still responds to heavy acceleration. I have accelerated full throttle to 100mph and saw max boost values of 29psi (stock program). On engine shut-down and restart the problem seems to reset itself and the truck will run normally for a bit before the failure occurs.

To correct the problem I have removed the banks equipment. There was no change. I have ordered the ICP short connector that will allow me to test actual voltage on the ICP while the engine is running. I plan to soldier some wires and run the meter into the cab for testing.

The scanner reads a desired ICP pressure as well as the actual ICP pressure. When the failure occurs both the desired and actual read 869.9 at less than heavy acceleration.

The scanner also reads desired RPM as well as actual RPM. Desired RPM remains pegged at 640rpm all the time.

Also, engine running the FICM voltage in is 13.5 and voltage out was 47.5.

On the very last test run I got two new codes: P2138 and P2140. I had run the truck with my foot on the floor on that test. Is this a glitch or does this play into my problem?