Ford 6.0L Power Stroke Diesel :: 2004 F350 - Low Idle RPM And Stall
Jun 3, 2015
Ok a little background on this truck. it is a 04 F350 6.0. Early build, with the ipr under the turbo an the earlier hpop. A few years ago the oil cooler blew on me and I got it rebuilt with a full bullet proof diesel kit and high flow egr cooler. Last year my turbo went out and I had it rebuilt and added a 5" MBRP turbo back exhaust. there have been multiple other parts updated and replaced but those are the major ones.
A few weeks ago I began loosing my oil pressure at idle. It was hard starting as well. I though that was from the cold winter here but it apparently wasn't. Before I had a chance to check the truck out, it lost all power on my way to work and staled out on me.
I just finished tearing into the high pressure oil pump. Found the ball plug was gone from the side. Tapped and plugged it. When I started it up it seemed to be idling fine. After it warmed up a bit i gave it some throttle and it would not go over 1000 rpm and spit out black smoke. Once the engine temp came up the idle speed dropped to around 300 rpm and eventually stalled. My oil pressure never dropped and the check engine light never came on. With the engine up to temp it will turn over and fire but as soon as I let go of the key it dies.
I do not currently have anything to get readings other than whats on the cluster. Do i have any options that wont cost me a ton to get my readings?
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I have a 2004 f350 with a 03 bullet proofed motor. The truck did not have any power and the turbo wouldn't support until I put a new vgt solenoid in and it ran great for about 3 miles... Stalled doing 65 kinda lacked power while accelerating but got up to speed quick. I pulled over and no start. It is running error code kam on pcm from disconnecting batteries but could this cause the stall and no start? Or should I be looking into icp sensor?
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I just bought a 2004 F350 6.0 cclb 6 speed with 260k on it. The previous owner seemed to have taken good care of the truck. It is basically stock with the exception of the blue spring mod, and a sinister diesel coolant filter. Anyways, I brought the truck home and it ran great. Now I have an issue that needs to be addressed.
The issue: I am experiencing a intermittent loss of power, stall, or stumble when engine is cold. After sitting all night the truck will start fine and idle fine. But when I try to accelerate and bring engine RPM up the engine will stumble and lose all throttle response, when this happens the WTS and WIF light flash. Sometimes it just stumbles, sometimes the truck will actually die and then restart. The issue seems to go away after the engine has reached operating temp.
I did some research on the issue and it seems there is actually a TSB out from ford for this issue. It explains that some 2003-2004 6.0's might have wiring harness chaffing issues. This is what the issue I am having seems like to me (shorting harness). I looked up codes on the truck and there is an active code (#8 glow plug circuit fault). I did a short visual inspection of harness and didn't see anything out of the ordinary. But i wonder if it would be worth changing both sides of the glow plug harness?
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While driving the other day, the truck suddenly began to stall when pressing the accelerator. The water in fuel light came on as did the glow plug light. This continued with the truck sometimes dying all the way and other times just stalling then picking back up. No difference in throttle pressure seemed to make a difference except that letting off totally then slowly pressing seemed to let it keep running sometimes.
So I get home and drain the fuel water separator. I gets about a thimble full of water and lots of the rusty looking junk others have talked about. Try to run the truck again, same thing as before. I then changed fuel filters and thought that had it licked but after about 10 minutes it started again. By the way, the 6mm plug seemed to have about a third of the threads rusted off. Not sure what that means as I drain it at least twice a year.
I have read a lot about the ICP and IPR issues and was wondering if this could be my problem. I am hoping its not the HPOP. My other thought was something in the fuel tank blocking the in tank filter. I checked the top mount bowl and it was only about two thirds full after running the truck
Truck info: Late 2004 Ford F350 Dually 4x4 crewcab, 6.0, EGR delete plate,4" turbo back exhaust with cat delete, no muffler,K&N filter and filter box, Diablo tuner usually set to 60hp upgrade.
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Its a 2003 f-350 6.0 started out just stalling out throw it in N it would fire right back up then started to sputter now I have a no start doesn't even try to start no smoke on crank. all of this between -3 and 5 degrees outside. According to my scan gauge ipr is 14.8, have ficm sync, ficm main is between 47 and 48 cranking, builds 0 icp irp duty cycle doesn't go up either. Pretty sure my icp is bad leaks oil though the sensor and pig tail is covered in oil. Truck has 197000 miles hpop, injectors, and ficm changed around 165000 oil cooler and blue spring at 1800000...
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I've seen the gods of the diesel engine do some amazing things on these forums, so after a year of pulling my hair out, I've signed up to try this myself.
This time least year,I bought a 2004.5 6.0L F-250 with 196k on it to haul around the state for my new business. At this time, I knew nothing about diesel engines AT ALL WHATSOEVER, but I've never been afraid to tackle anything and mechanics are not totally foreign to me. Not to mention, I was hoping everything might just go peach-ily for at least a couple years. (for what it's worth, My dad and his family are mostly shade tree mechanics and I'm a power plant operator so mechanical concepts are not totally foreign to me, just never had a diesel before)
To begin, I purchased the truck and everything was fine for about 2 weeks. Then abruptly one morning I noticed a couple of hefty surges on the way to work. Then, on the way home I thought all was well until about half way home, it did it again! as I was pulling up, it galloped once I pulled my foot off the pedal. like ba-DA-DA-DA-da-da-da-da-da-da-DA-DA-DA-DA-DA-da-da-__ and then STALL! Shaking with concern over potentially an awful purchase, I turned the truck back on only to find... that it's fine?!?? No problems for the next two days and then it happened again. then good for a week, then again. then good for 2 weeks, then again. so then I bought auto enginuity and an edge insight to do some troubleshooting. Let that sink in as I explain it's history a bit.
-All but one injector is ford remanufactured the other is stock (was never told which one)
-replaced head gasket with another OEM
-ARP Head Studs
-EGR delete
-HPOP AND STC fitting both replaced
-FICM replaced
-Oil cooler replaced 50k ago
-ICP and pig tail replaced right before my purchase
- Has been through roughly a handful of ICP's since I've had it (I'll explain)
-I've cleaned the EBP tube a lot and updated it to the newer ford sensor with the flare fitting
-I use Rotella T6 5W40 and CAT ELC-1 Coolant.
-Deltas are under 10 at normal driving
-I typically drive under 2200 rpm until warm then like a banshee at operating temps.
Now one year later, its not fixed, but I feel like I'm close.
The DTC's I have seen are ICP sensor circuit intermittent (I think po2884) and Power Blance contribution failure from cylinders #2 #7 and #8 but never at the same time.
Every time I replace the ICP, it will be problem free for about 6 weeks and then it will return full force (surging and galloping when warm about 50% of the time)
During a possession I see the following:
*Cylinder power contribution test yields no issues at idle or when cold. when "possessed", the whole baseline across all cylinders goes up and all cylinders dip and return at random. none singled out
*ICP voltage fluctuating from ~.6v to 1v (.24 @koeo) *Also during a surge*
*ICP PSI dancing up and down ~600 to 900psi (0.0 @koeo and ~500 at normal warm idle) *Also during a surge*
*IPR% bumps up and down ~25% to 30% (15%@ koeo and 23% at normal warm idle) *Also during a surge*
*FICM Voltage anywhere between 47.5v and 49v
*EBP is normally 15-20 psi
*Boost is 1-7 normal and is not affected by "possession"
These numbers have taken a long time to get since it will only be possessed for about 3-10 seconds at a time and then will disappear for days. The stall has only happened about 5 total times in a year. The surging is much more frequent. I usually get a buck or 2 on any given trip that is longer than a half hour but NOT IMMEDIATELY AFTER AN ICP REPLACEMENT.
On one occasion, I noticed that the ICP PSI actually tanked to about 350 right before the IPR went from 25% to 40% right before a posession. I was driving about 35mph through town at the time.
Here's my thoughts...
- Did that one occasion clue me in to an intermittent HPO system leak causing the truck to briefly over-compensate by spiking the IPR?
- Is my ICP pig tail jobby done incorrectly? If there was a short, wouldn't I see the volts drop to 0? I have another one and will replace to rule it out.
- I have yet to test my fuel pressure, but I figured if it was low, I would have lost injectors by now. (I replace filters probably too often but next empty tank, I'm dropping it and checking the screen and strainers)
I should also mention that I have buzz tested the injectors and I can hear each one clear as day, and that for REALLY long trips, it actually returns to normal. In other words, my window of death is between 30min and 2hrs of driving; invincible after.
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Well, after getting the bed back on my '05 F350, I have been driving it on the road for a few days, but now I have a new problem.
Every once in awhile I get lag off idle for about a second, then the turbo spools and everything is fine. Other times, I step on the accelerator a bit from a stop, and the truck acts like its going to die for a moment, a puff of black smoke, and then the turbo spools and all is back to normal. It a combination of these two problems happens about 3-5 times out of 50 stops a day.
I have a scanguage and everything looks normal and I never get any codes when I check.
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I have a 2005 F-350 Lariat, FX4, CrewCab, with an 8ft Bed if any of that matters. Currently sitting at 191,000 miles and 4,500 Engine Hours I just started running into some issues that I cannot figure out. To start with here is a list of all the mods and prior maintenance that I've done to my truck over that last 6+ years that I've owned it.
I purchased the truck in 2010 and had no issues whatsoever for the first 3 years.....then it all started. While pulling a camper home from vacation "still bone stock" the truck overheated and by the time I realized it it was to late. I ended up blowing a head gasket cracking a head and blowing a hole in my coolant reservoir from the heat & compression of the engine in the coolant system. So to the shop it went.
All of this was done at the same time at just under 4,000 engine hours:
1) Both heads were sent out to be pressure tested "which is where the crack was found", so 1 replacement head and the other trued up and tested by the machine shop
2) All 8 injectors replaced with Airtex/Wells New/Reman
3) ARP Head Studs
4) BPD EGR Cooler
5) New Stock Coolant Reservoir
6) New Stock Oil Cooler
7) Motorcraft Coolant & Oil/Oil Filter Change
8) New Serpentine Belt
After getting the truck back I installed some upgrades that I had wanted but didn't want to do until I had head studs. 4" Turbo back Diamond Eye Performance exhaust, Bully Dog GT Tuner with an EGT Pyro, coolant changed to Caterpillar ELC, Sinister Diesel coolant filtration system, new Optima batteries "I hated them",
Forward a year with no problems I had a crank but no start. I ended up having a bad IPR. A buddy rebuilt the turbo since I had it out and it was leaking. He apparently did something wrong because it took its own life sometime after. So a brand new stock Garrett Turbo with a Wicked Wheel 2 & I changed the IPR "don't remember the brand." Also replaced the factory paper air filter with a cleanable one from AFE that fits in the factory cold air intake.
Little more time and I started to have some overheating issues again, luckily the Bully Dog was monitoring and I had alerts set up so I caught it way before it caused any serious damage. Turned out the fan clutch wasn't working. So I replaced the Water Pump with one from dieselsite.com that has a steel impeller, also replaced the computer controlled fan clutch with a 7.3L mechanical fan clutch and an adapter from BPD.
After that the batteries I hated were replaced. I installed Oddssey Extreme 950CCA ones, a new 185A alternator from FICMRepair.com as well as the complete battery wiring interconnect kit. Did the blue spring upgrade. Replaced my FICM with the BPD 6 phase at 54V setting. Also I changed my starter to an 6.4L Ultima one from O'Reily Auto to bring me up from that slow crank of the 6.0L at about 150RPM to the 225RPM of the 6.4L.
So now on to the current issue. This has happened in the last month and may be related to the issue. I had some small coolant leaks and wanted them fixed. Pressure tested the system & found the radiator and timing cover gasket leaking. I installed a new stock radiator and lower radiator hose. Had the shop do the gasket and a serpentine belt due to cleaners being all over it. During replacement of the timing cover gasket my mechanic found that the LPOP gears had some damage as if something had be in there at one time. Not sever damage just minor. LPOP replaced with brand new one from Ford.
After I got the truck back it was fine for 2 weeks, no leaks or any problems whatsoever. Then I noticed a hesitation as I was leaving work at idle. You could see the RPM's moving up and down by about 50 as it sat there at idle. It got really bad and eventually stalled on me. It fired right back up and ran fine after. I was thinking water in the fuel or just maybe old fuel because it was kinda old and I was at 1/4 of a tank. I went and filled up and it ran great all the way home. Day or so later same thing. At idle you can see the RPM fluctuating and while driving it feels like it has no power at times then it goes away and runs fine. So I changed both fuel filter with Motorcraft ones and put in a new oil filter. It is the Wix brand but I've be running it for years with no issues, one was also in it way before this issues started. The oil has about 2,000 miles on it currently. I verified fuel pressure at idle to be at 70PSI. I tried unplugging the ICP at idle with no change in the hesitation. So I plugged in my SG2 and started to see if I could see anything out of the ordinary.
OAT - 60 Degrees F
KOEO Engine Cold - FMP - 54.5V, ICV - 0.25V, ICP - 0, IPR - 14.9
KOER Engine Warm - FMP - 54.5V, ICV - 0.82V, ICP - 576, IPR - 23.5
Cruise at 40MPH - FMP - 54.5V, ICV - 1.14V, ICP - 965, IPR - 32.9
Cruise at 50MPH - FMP - 54.5V, ICV - 1.42V, ICP - 1,190, IPR - 38.0
Cruise at 60MPH - FMP - 54.5V, ICV - 1.27V, ICP - 1,143, IPR - 37.2
While driving this issue comes and goes very randomly. The only parameter I notice changing alot is the IPR. It jumps around a lot and sometimes it will go to 85. I know that this isn't a good thing so I am going to change the IPR later today or tomorrow. I already had a brand new Motorcraft one to put in, plus at the very least I want to look at the screen. I had read somewhere that there could be air in the oil system and that if you run at a high RPM it can remove this air. I never seen any bubbles or anything on the dipstick. My brother ran the truck for me at 3,000RPM for 5 minutes. No hesitation during the test but he didn't have the SG2 plugged in so I don't know the parameters during the test. I thought that it worked but then it came back after a few miles of driving. The above parameters are from this mornings drive home from work.
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I have had literally no issues with my 2004 F250 Super Duty. Went out and started the truck like every other time for the past 13 years. Started backing out of the driveway and burped the throttle and it just quit??
I put back into park and it rolled over for about a minute and finally caught. When i put it back into gear i had zero throttle response. I have a NOx sensor fault code and and EGR fault code. I replaced the FICM 2 years ago.
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My truck is a 2005 f350 6.0, all stock except for an egr delete and 4 inch cat back exhaust. I recently did an oil cooler replacement and egr delete, resealed all 8 injectors, and fixed some wire chaffing at the FICM. it's running great with the exception of idling. It seems like it's idling low but the gauge stays at 750. If I hit the high idle switch, it does fine. Red lights are stressful because it shakes and sounds like it's going to die but never does. I'm posting screenshots of my Torque pro.
I have a SC2 as well but I honestly like Torque better so that's what I use most. I know my ICP is low, but 8 don't know why. No oil in the connector, and no change when I unplug it. The ICP sensor may be a month old with 1000 miles on it. This was taken at a hot startup, sitting in park. When i say hot, I mean I had driven about 60 miles. This is sitting still in drive. ICP voltage finally climbs over 1.0 when i get going about 15mph at around 1250 rpm. The second pic the ICPV is actually higher than normal. It usually stays at .8 until I give it gas.
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A while back my 05' f350 6.0 was having rough starts and an erratic idle. It died coming up to a stop sign it started back up after 2 cranks and then it did that same on the way home. The next day leaving work it wouldn't start. I knew i had a couple injectors on the way out so i decided it was time to replace all 8 upon tearing it down i noticed my oil cooler was leaking so i figured it was time to rebuild that and finally do the egr delete that i had been wanting to do. well i put it all back together and got a no start.
The dash gauge on my oil pressure is reading normal when i cranked it so i went and bought a scangauge2 to read the icp its hitting 1500psi when i crank it. The ipr% is reading good. But my ficm main power is at 26v with the key on then it drop to 14v while cranking and eventually down to about 9v. Its never at the 48v that its suppose to be at. The scan gauge is also showing that my ficm sync=0. Would the sync be showing 0 since the ficm is bad? My batteries are fully charged and i have both of them on the charger while I am cranking it.
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Was driving my truck normal, got to a stop and the truck staring to idle high and like stuck on third gear and also the tow light (over drive) started to flashing Is like the truck put it self on safe mod. Drove it back home but couldn't do more than 55 miles n hour so I didn't hurt the trans.
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2003 F350 6.0 with 290k+ ... It has a skip in the engine at idle and running. At times when running down the road skip seems to get worse. Changed both fuel filters, didn't work. Truck start up is normal, no leaks, and flashing no codes.
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2003 f350 dually. Fully bulletproofed about 10k miles ago. Everything was running great for about 5k miles. A friend of mine got stuck and I went to pull him out. Got him out but got on it really hard...never overheated or anything.
Next day truck throws a cyLinder 5 contribution balance code. Ran ok but idled rough. Pulled injector and put a used one from a running truck in it. Code went away and runing fine for a few weeks. Took a long trip from FL to Texas, and on the way home same code occurred but idle was not as bad. I would clear the code and it would be fine for a few hundred miles, then would show up again. Made it home, still was driving around town a little with the code only showing sometimes. A couple blocks away from home taking off from a stop sign lost all power and motor shut off. Turned out the Injector o ring blew and hydrolocked the motor.
So now, ordered all new 155cc30% injectors , 58v ficm and new oem injector harness. Installed and Drove the truck to Illinois. After about 700 miles I noticed a little rough idle and had a cylinder 4 cont code. Made to Illinois and back to fl. At fl line I had cyld. 4 and 5 codes now. Cleared and cyld 4 was gone but 5 stayed. Got home and balance test showed 4 and 5 bad injectors. Sent them off to be fixed just got them back in. Truck started fine, smooth idle, ran for about 10 miles and cyld 5 code come back and so does the rough idle. I'm at a loss now.
Will be doing compression test tomorrow. Other than a rough idle truck runs flawless, will roast the tires and pull anything hooked to it. No hot starts, no symptoms of anything else. Possibly a problem with the oil rail feed on that cylinder? Main ficm harness? Bent pushrod?
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I have an 04 f-350 that I did an EGR delete, new Ford oil cooler, new radiator (not ford), new thermostat (not ford), coolant filter, glow plugs and harness, MBRP theoretical 4in downpipe (was 3.5 to converter) flushed cooling system with lots of tap water before the delete, replaced coolant with Cat 1 ELC and distilled water, fresh T6 5W-40 and filter, several weeks ago. Was troubleshooting a wireing problem and found what looks like oil sludge in the degass bottle while under the hood.
Possible that while doing EGR delete I clipped a gasket? Truck runs great, no smoke out the tail pipe. There is what looks like about a cup floating on top the coolant. Oil level is down about a 1/2 quart and clean, no water in it. Where do I start looking?
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I have a 2004 Ford f 350 superduty. Everything runs great. Now the other day my fan came on and stayed on for three days now. It goes with my rpm so when I am doing a 100 down the highway in hopes it will disengage but won't.. Everything is Stalk.
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I have a 04 F30 4x4 with a sick 6.0 power stroke. It has 230k on the mileage and ran good. I was driving at speed when she started missing like it had lost an injector and loosing power. The RPM's dropped under 1000 so I had to pull over off the highway. When i pulled over and put it in park it shutoff. Tried several times to get to start but after 10 minutes it started up. I drove about 2 miles and it started the same process. This went on 2 more times before I was able to finally limp home the 40 miles.
It never shut off again but ran very poorly. I put a new valve in and when I tried to start it just mad a pound clunking/clacking noise. The repair shop put a starter in it because it had stopped engaging and was going to ruin the fly wheel. I looked at it and it was eaten up pretty bad from trying to get the engine to turn over. So now all it will do is a single clunk and will not turn over. He says it could be a bad injector that flooded a cylinder or blown up in the bottom end. He did take serpentine off and still no go.
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About a month ago my truck was cutting out at one point it wouldn't even crank, got it going took it to the shop found my driver side battery clamp cracked, replaced it aswell as the egr valve because I had a p0401 code. Valve was pretty gummed up. Now recently it started doing it again. It cut out and it started right back up then later that night drove it two blocks and died, turn the key on and my glow plug light stayed on and wouldn't crank, was checking over all my connections and nothing seemed to be wrong. And then randomly it seemed like everything reset and my injectors would buzz, glow plugs cycled and fuel pump kicked on and started right up and drove home.
I replaced the pcm relay because one terminal looked to have gotten hot. Let her warm up in the driveway and she cut out twice but started right up. Checked over the connections again, replaced and cleaned both batteries, took it for a drive and no problems, later on started up again and let her warm up and cut out again, this time I got the p0401 code again. (Egr insufficient flow). I'm at a loss not sure where to keep going. It's an 04 f350 with egr delete, banks turbo and intake, with edge juice with attitude tuner on level 3 never switched levels around. And some other add on and mods that could make the list go on.
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2004 later year 6.0 F-350. 155,000 miles. All stock.
It will start and run fine. Drove it for an hour then began running rough. Nursed it back home. When idling it eventually died. It will eventually fire up but runs really bad. It has done this a few times. I've done fuel filters and 911 fuel treatment because thought it was gelling. No luck...
It has injector circuit fault codes that pop up. Only other code is MAF sensor low but in range. First it was codes for cylinders 3,5. Then 3,5,8. Then 1,3,5,8. Now just injector 1. Keeps changing as I refresh. Battery power fine. FICM is 47.5- 48volts and in sync. ICP at idle is 600-700psi. IPR is 25%.
We had a problem with blowing turbo pipe off so may be overboosting. Not sure. No code thrown relating to that. Possible wire chafing? Maybe bad tank of fuel? Not sure where to turn at this point.
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A little background, this is an 04, f-350. It sis not start a week ago so I charged the batteries and it started, started fine this morning, (had not driven it for the week) Drove it to work, 35 miles, parked it, and it will not start.
I downloaded Torque and got a few numbers,
HPOP 1900 FMP 48V (repaired last summer) and FVP 11.5V.
Ran out of battery to surf more and look, so I am trying to figure out the app, and the issue with the truck. It seems to turn over good, until I ran the battery down, and the GP cycles normally, and the injector buzz seems good. Temp is in the 50's...
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I have a 04 F350 Dually and I am not getting any oil to my high oil pressure. Truck will crank but won't turn over. The high oil pressure pump is fine. What am I missing?
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