Ford 6.0L Power Stroke Diesel :: 2005 E350 6.0 - Tough Start And Check Engine Came On


Feb 8, 2017

I've got a 2005 E350 6.0L with a 4x4 conversion and Sportsmobile penthouse roof. We barely made it out of Big Bend NP yesterday. Here's the protrusion of events...

Had rough starting for a while (separate conversation). Yesterday AM had a tough start and check engine came on. We were about 5 miles up a dirt road, no major off roading but dirt and bumps along the way down. Throughout the day made a handful of stops/starts. Each time battery light would stay on and then go off after getting to about 2k RPM. On the drive out I noticed the battery gauge decreasing.

Turned off all radio, lights, etc. Kept dropping and eventually the "limp home" mode kicked in with the battery gauge below L. Maybe 20 miles of safety mode at 50mph all gauges went off. Still driving. Another 5 minutes all gauges kicked on and showed normal. Stopped, turned off and restarted and drove normal the rest of the way into town and full highway speeds.

I have it in a shop now but would love to back up what they might tell me. My guess. Loose connection to alternator or battery somewhere. I originally thought the alternator had crapped out but it having kicked back on with no issues for the last 30 miles makes me think that's not it. Batteries are only 3 months old. Battery gauge back to normal today and started up/made its way to the mechanic no problem.

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Ford 6.0L Power Stroke Diesel :: 2005 / E350 Van - Rough Idle Stalls / Hard To Start

Rough idle I have had for little bit.Would stall out at idle or a stop, but fire right up? No one could figure it out with the stalling, but now its bad, started yesterday. Have white/blueish smoke sometimes, ( white smoke smells fuel) on restart after warmed when it dies, first time it took 25 mins to restart, now only takes 5 to 15 mins, when I step on it INCREDIBLE full power, fuel mileage gone to hell also since yesterday. Had full tank, now 1/2 tank.

No problems on cold start at all, no check light, 325,000 and never had this before.

Bad fuel?
ICP?
FICM?

Recent work, new turbo, ( turbo was original turbo installed when built) cooling line to waterpump, oil change, new fuel filters, front brakes and 2 new batteries.

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I just got a new 2006 E-350 van about 4 months a go (my previous 2004 got scraped - found out the fuel line leaving the secondary filter into the engine with clogged with bits of paper (wtf?)... after I decided salvaged it for parts for my new van...).

New van drives beautifully in the last 4 months without problem, but shut down on me on the highway yesterday. No strange noise or anything when it went out. I managed to coast safely to the side of the highway. Unfortunately, I cannot seem to start the truck again and had it towed home. It cranks, but doesn't start.

I have a scan gauge ii this time and it shows the following:

KOEO:
FICM ~48.5V
ICP 0
IPR 14.8%
Sync 0

Cranking:
FICM ~48.5V
ICP ~8PSI
IPR 84.7%
Sync 1

I still have a P0299 and P2262 check engine code from 2 days previous to the above, but this doesn't seem to be related to the no-start conditioning (both turbo related)

So, pretty much, I'm looking at a very low ICP. Some research indicates this is is due to a bad HPOP, bad STC fitting, or a massive leak. Given the really low ICP, can I rule out the STC fitting and leak? Looks like only the LPOP is providing pressure. Is there anyway to tell if the HPOP is dead or not once I remove it?

Anything I should shot-gun replace first? I have a bunch of salvaged parts from my old van in my garage, which doesn't include the HPOP unfortunately.

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Still weak.. I'm thinking its most likely low pressure coming off the pump and maybe it's time to replace I haven't crawled under there to inspect placement of pump. Thought while there I would also replace the reservoir.

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Could this be contributing to it? Could it be a head gasket? now being a diesel mechanic I doubt its a head gasket simply because there is no oil mixing. I am praying its nothing too major. Once I have the narrowed down to what it could be ill see if its something I could tackle or if the stealership has to do it, which I am not looking forward to. I'd rather be down a truck for a little bit and save a boat load of cash.

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I bought a 2004 E350 van that has been driven 9000 miles in the past 6 years. Replacing a thermostat in an E350 6.0 Powerstroke van?

My van is running on the cold side ECT 176-180 when idling. It will reach 190 when I am driving. The EOT is 6-10 degrees higher.

I am flushing the system with Restore and plan to replace the T-stat soon when it arrives from Amazon. I have 3 gallons Cat ECT-1 full strength coolant and a lot of distilled and reverse osmosis water for the flush.

Is it a long procedure? There is not much room in a van to work with ease. If it's too involved, I will find some over time at work and pay my mechanic to do the install.

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When I dropped my 2 frame rail batteries I noticed the clamp on the positive battery cable was broke. How to splice in a new clamp?

Pick and pull is an option. I would rather repair my OEM cable and be done.

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The pressurized coolant reservoir has a crack/leak in it. Is it wise to only replace it, or should I look for a root cause? The temp gauge does not go past 50% pulling hard up a mountain pass.

This was a fleet vehicle that was pretty much abandoned. There is a chance the reservoir was cannibalized for another rig and had the bad part thrown there but I'll never know.

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Ford 6.0L Power Stroke Diesel :: 2005 - Won't Start When Hot

My 05 F350 will not start hot, occasionally stalls when hot as well. Starts immediately when cold and runs smooth as silk. Truck has 138k miles on it, I bought it studded and deleted, running 5w40 Rotella T6 with Archoil. Some history on the issue: Started out with a rough idle, found low FICM voltage along with a bad battery. Replaced both batteries and FICM, problem fixed. Soon after developed a misfire with a cyl 5 imbalance and injector code, replaced all 8 injectors which fixed that issue.

About 2 months ago I had a no start problem, turned out to be a bad ICP, replaced that and the harness and was all good for about 3 weeks. That's when it started becoming hard to start when the motor was warm, and then no start at all when hot and would stall occasionally at idle, wait an hour and it'll fire right up!

Ran the air leak test, found a leak on the right bank standpipe, replaced the dummy plugs and standpipes, no start still remained. Went on to replace the IPR and STC fitting which didn't work either. Now it throws a P2285 code, low ICP. Ran the air test again and I don't hear any leaks. HPOP seemed to have good compression turning by hand.

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New here but long time lurker. I have a 2006 e350 with 6.0, bought it from a friend not long ago. The work that has been done to it the last 50,000 miles is as follows.. New hpop, all new injectors, egr delete, sct tuner, stand pipes and dummy plugs. I had it for a week and would get a no start hot once in a while. This issue had become worse and the truck started to stall as the RPMs dropped. Reading here i replaced crank sensor and the stalling stopped but the no start hot continued. I took it to a local diesel repair shop and they did the following..

Use a test ipr (no change), replaced ipr pigtail (was cracked) air test (leak under pass valve cover) replaced stand pipes and dummy plugs on this side. They said no leaks and I was good. Truck worked as its supposed to for 1 day and the no start hot issue reared its head again. Took it back and now they say the hpop is bad. The pump that was put in about 50,000 miles ago was a bostech? do these go out? Sangauge reads good ficm, but seams ipr doesn't climb that quick.

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I came home and drained the water drain on the filter, didn't see any water but hoped it would solve the problem. I cycled the key a few times and started the truck but the light is still on. My truck is a 2013 f350 6.7 and has 211500 ish miles on it. I bought it a month ago with 18500 miles and haven't had any issue until tonight. My only thought is maybe the fuel filters need changed. I don't know if or when the previous owner changed them.

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I started my '16 6.7 this am and drove it about a mile.

The check engine light came on and at the same time the display said "Reduced Power". I decide to turn around and try to make it back to my shop but shortly after turning around the display said "Low Fuel Pressure" and within a couple of hundred yards it shut down leaving me stranded by the side of the road.....

I called my local dealer who gave me the Ford Cares 800 number. I got a flat bed in about 1.5 hours which I didn't think was too bad considering I live in the country and they brought it to the dealer. The SA said it might be a couple of days before they could look at it as they were pretty busy... What it could be? The engine is stock with 9100 miles on it...

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