Ford 7.3L Power Stroke (1999-2003) :: Stalls Randomly And Sometimes Will Not Start
Nov 2, 2015
2001 Excursion 7.3 - stalls randomly, sometimes will not start. After the IPR was replaced it was rough for about 4 miles (I thought maybe air in the system), next 40 miles was flawless with 3 stops and restarts. Then it sat for a few hours and I went to leave again and the problem was off and on again for another 5 mile drive. Now it won't start in the driveway. It will start if I disconnect the ICP but the idle is still a little rough.
I replaced the normal culprits after a lot of searching on here:
CPS - replaced with autozone part, thought maybe it was bad new so went to ford and replaced with official part from the dealer
ICP - had oil in the plug and it would idle better removed so I replaced the plug and as much wire as I could - soldered, heat shrunk, good connections - both the pigtail and sensor came from Ford dealer
IPR - replaced with part from the Ford Dealer (FYI - 1 1/8" 1/2" drive craftsman deep socket from sears fit in the ratchet and on the part).
Grounds - found somewhere that the ground on the firewall for the windshield wipers can interfere with the CPS so I pulled it, clean the connections and made sure it was tight and secure.
No check engine light now - I received a few through the process, but did not clear them and there are no codes at this time (self cleared on the 40 mile drive)
I'm thinking it may be some electrical issue/short or a fuel issue at this point, bowl is full and the filter is fairly new (few thousand miles). I haven't done the Hutch mod, but have over 1/2 a tank.
I'm trying to get this going as quick as I can so I don't want to waste too much time, but I also don't want to miss a critical troubleshooting step to take.
Below are my thoughts on the next steps.
Research and test fuel pressure
Tow it somewhere to test each injector - I only have Torque pro to read codes and engine status
If fuel delivery checks out ok, start testing wire by wire on all of the above parts.
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1999 7.3l 6spd standard 4x4. Just bought the truck 4 months ago knowing it had a problem that once warm occasionally would t start. Happened a few times every week or two. But wait 15 minutes and the truck would fire back up. Then it started happening more often throughout a day. And I would have to wait longer for it to cool to start it up.
Icp has been changed
Cam sensor
Pulled valve covers to check to see if there were any injector o rings failing. They were all good. Put it all back together.
Pulled the IPR and tore it apart cleaned it all out
Started driving it ran great for a week. Then today sitting at a light the truck died just as if I had turned the key off. Wouldn't start for 3 hours. The. Fired up. Took it to buddies show and started checking things out again. Both batteries load test great and fully charged. Alternator pumping out 13.5 and up.
Codes i have pulled are waste gate to high /low
I forget the number for that one. The second was P1211. Cps has been changed and ipr cleaned. Think that I should replace the ipr of this happens again?
I did get w code a few weeks ago about low voltage at module. this code doesn't appear anymore. Since I checked the plug ins all looks good. But the PCM wasn't mounted properly. So I fixed that up and checked battery connections. They were very good so I re did all of that.
Anyway. Back to the problem. After ipr clean. Drove as she should until sitting at a light a week later. Truck just quit. Would t start back up until cold. Any thoughts. New IPR? Oil in hpop within half inch from top. And I don't seem to have any oil leaks. Did oil change fuel and air filter. Not low on any fluids. I had a 1997 too and threw a bunch of cash at it like this one trying to find the issues.
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As would be expected things deteriorate on a 16-year-old truck. My alarm has, on a few occasions, decided to annoy anyone around by activating for no apparent reason. This has happened in various conditions (in the parking lot, in the driveway, right after I've driven it, or sitting half the night). I chalked it up to aging circuitry.
Now I've picked up something new. Over the last few weeks my truck may or may not arm. It seems to be a flip of the coin. I'll drive to the store and I push the button on my remote and the truck goes "beep"..."beep". 10 minutes later I drive home, park the truck, push the remote, and the truck goes "beep"...and that's it. My alarm light is blinking two quick flashes when this happens.
Since this has started my truck has begun randomly having a delayed start. I'll disarm the truck, turn the key, and nothing happens for about 1 second or so (seems longer) then the truck starts normally.
Both of these issues started pretty close to the same time. I would normally go straight for a starter issue but I don't know if these might be related. I'm the second owner so have absolutely no idea about the Ford anti-theft system, how it's connected, or what the blinking lights mean.
I'm considering disconnecting the anti-theft system to see if that makes a difference but, as stated, how it's connected, what I might disable, or how it works. Was there any documentation published on it?
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I have a 2001 Excursion 7.3 Diesel that is having a starting issue. Have replaced the batteries, has new glow plugs, common failing cam position sensor replaced once already. It runs great when it starts, no codes. It will crank, but not turn over at random times. Will do this for 3 or 4 tries...charge the batteries, go back later to start and it will on the second try. Turn it off, try again..and back to cranking, but not starting. Not fun having to worry about being stranded somewhere. Absolutely desperate at this point.
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2003 7.3 excursion.. The truck starts every time revs up and idles about 3 seconds then the rpms drop and it tries to stall out catches itself then revs backup and idles rough similar to if you have got air in the fuel lines from changing the fuel filter.. About 1 in five times the truck will stall out and it starts and immediately and idles rough but the rpms and everything runs at speed and rpms don't drop again! This is a reman engine/transmission recently installed.. The mechanic who installed it was unable to figure the problem out.
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I have 2001 F250 7.3L 261k miles.
Over the last few months, I have noticed that my truck is taking longer & longer to start after sitting for a long time (i.e. every morning, after work, etc.) When the problem first started (3-4 months ago) it would crank for 2 seconds & nothing so I would turn it off, let the "wait to start" light go off again (depending on outside temp 10-20 seconds) & then it would crank & usually fire right over like it was new. That seemed to happen only in the morning when it was 70 degrees or colder outside but no problem after work when it was 80+ degrees.
As the weather has gotten colder, it has gotten progressively worse. A couple of weeks ago, it was in the 40s in the morning & it took a solid 8 or 9 minutes of cranking for a few seconds, then trying again before it started. Once it started it did "chuga chug" a couple of times before it smoothed out. Last week when it was 16 degrees in the morning, it wouldn't start at all. I tried for a solid 15 minutes before I gave up.
I will say that as it has gotten worse over the last couple of months, I have noticed that it's cranking w/o firing but I will hear it fire once or twice per crank before it will fire up & run. Once it starts, it runs like a champ. No studders, stalls, slow acceleration, etc. Pulls like it always has. The weirdest part about it is that once it starts & runs for 30-60 seconds, I can shut it off & it'll fire right up every time. If I get it up to full operating temperature, I can go back & start it right up 2 or 3 hours later w/o a problem.
I did notice my oil cooler is leaking pretty badly (that will be fixed this weekend) & my valley has fluid in it but it's hard to tell if it's diesel, oil or a combination of the two because my truck is setup to run on WMO (waste motor oil). I have dual tanks so the OEM tank is diesel & the auxillary tank is WMO. I have 2 mechanical fuel pressure gauges on my fuel bowl, 1 pre & 1 post fuel filter as well as an aftermarket Walbro fuel pump. The fuel pressure when running on WMO has always bounced a little bit between (65-75 psi) but the fuel pressure on diesel has always held solid at 75 psi until recently when I have noticed that it flutters a very small amount between 73-75 psi.
I have verified that the GP Relay works & was leaning towards a glow plug problem but considering it was having troubles at 70 degrees ambient temperature, I'm hesitant to think that's the true problem. I think that might just be adding to the problem. I live in the south so my truck doesn't have a block heater but I'm going to add one this weekend when I replace the oil cooler gaskets & o-rings.
I'm also going to pick up a new Android tablet today (replace my broken one) so I can use the Torque Pro app to monitor ICP, HPOP & InjPW. Finally, I had a DP Tuner chip on it & to remove that as the possible cause, I removed it & the same symptoms continued.
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So the truck has been stalling out and dropping power randomly, symptoms pointed to needing the 50 cent mod, changed the cps for cheap insurance and peace of mind just in case it wasn't the uvch, no dice. So last night I yanked valve covers for the first time here's what I did while I was under there, check my work.
1st I ohmed out injectors thru the 42pin harness according to tuglys sig link. My meter would only go down to a 0.4 when testing the test leads just to each other
DS injector ohms
#2 3.5
#4 3.4
#6 3.6
#8 3.6
PS injector ohms
#1 3.6
#3 3.6
#5 3.5
#7 3.6
DS glow plug ohms
#2 prong to ground 2" away 0.9 ; white connecting wire back to gp relay 0.3
#4 0.9 wire to relay 0.5
#6 infinity ohms up thru highest meter setting, checked multiple times and different ground spots,(replacing tonight) wire to relay 0.5
#8 0.5 wire to relay 0.5
PS glow plug ohms
#1 1.0 ; white wire back to relay 0.6
#3 infinity multiple tests as well (replacing tonight) wire to relay 0.5
#5 0.9 wire to relay 0.6
#7 1.0 wire to relay 0.7
Next up, ebp sensor was reading 1.9 higher than map/baro koeo, gently cleaning sensor earlier didn't work. Installed new motorcraft, will check it with Torque pro koeo once the batteries are reconnected
Next I checked the uvch connections which felt good, darn it, maybe a smidge of movement from the DS, but nothing halfway disconnected or anything. Hmm. I ground down the quarters to the top of his head and installed.
Next I torqued down the 4 bolts per cylinder of the rocker arms at 20 ft/lbs, all were perfect and snug
Next up, injector torque. I've read on here below 50, or 80 in/lbs depending on different threads and opinions that I would need to replace o-rings.
So I set the in/lb click torque wrench at 50 in/# and tested the wrench's click on the higher torqued rocker bolts, then checked all the injectors, all were good
Reset for 80in/lbs, tested, then hit all injectors, #6 almost budged but clicked immediately before the handle moved
Reset for 100 in/lb, tested on larger bolt, 2 injectors took a 1/8 turn;
Reset for official spec of 120 in/lb , tested wrench, all injectors took 1/3 to 1 full turn
Reset for 130 in/lb (above official spec, but highly recommended on here by those way more knowledgeable than me on our engines) tested on a larger bolt, slowly and carefully gave all injectors almost an extra 1/2 turn to click; whew, finally a relaxed sphincter.
At this point I knew I needed to buy 2 glow plugs today, replace, then I'll check all glow plug torque at 14 ft/lb in one go, so I got everything ready for a hot torque after I do glow plugs tonight ("unloaded" the torque wrenches) and finally installed the RiffRaff AIH delete plug. My cell phone's alarm went off to get the kids ready for school, so hit the snooze and got everything put up. Now for a nap, then buy 2 Motorcraft GP and check back on here before going back at it tonight.
I also checked the turbo for play in all directions, was nicely solid and spun smooth, no wheel damage. Up pipes and well basically everything exhaust under hood had zero signs of soot/leaks with inspection mirror.
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My 7.3 will cough randomly on the interstate not towing or anything. It has a new turbo and filters...
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Truck has a rough idle and finally just stalls out. I replace the under valve cover wiring harness and put in new glow plugs. With valve covers still off I started the truck in the issue still persist. I went ahead and unplugged each injector and each time the motor had a hick up .
What am I pulling apart and replacing next?
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Lately when I am coming to a stop and roll up to a stoplight/sign in gear the rpms drop too much and it stalls. I let the clutch back out and it starts back, but will stall again if I coast in gear again.
If I just push in the clutch without the rpm's coming up like to change gears it doesn't stall, only when I downshift when stopping and then once I push in the clutch the rpms drop and don't recover.
Truck runs great otherwise, new motorcraft icp and cps doesn't work. Thinking maybe ipr, but idk. I can rev it in neutral and it doesn't stall only when it's under load coasting, it's like the injectors don't recover from being off while coasting in gear.
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When driving my truck it coughs randomly not towing or anything going about 70 mph drops rps slightly and goes right back. It has 212000 miles new turbo and filters...
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Ok, so my 2002 f250 died on me last Tuesday out of the blue, pulled it home and found fuse 23 I think ECU power was blown. I removed my Hydra, and put a new fuse in it and all seemed well, then Friday evening on my way to dinner was driving along and truck shuts off like someone turned the key off. I replace the Crank sensor, even though I had put a new one in after the first time it died, which was last Tuesday, still would not start.
Pulled it home, went out Saturday morning to look at it and hit the key and it fired right off. At this point I don't really know where to look, I wiggled every wire I could find while it was running Saturday and no change, but it does seem to have a miss in it while it is idling...... I am not sure where to start looking....
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My charging system light in my 2000 F250 keeps coming on and off and very random times. Its been happening for quite sometime now and I finally joined FTE so I figured I would ask everyone what could be causing this. Ive disconnected all the electrical plugs from the alternator and made sure they were in there well.
It all started when I was cleaning my engine not too long after getting the alternator replaced. I don't remember getting any water anywhere near the alternator and cant understand anything causing this other than the connectors. It will cut on and then cut right off sometimes and then sometimes it comes on and stays on...
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My engine suddenly stops while driving. There is no warning or loss of power, it just stops randomly after running fine for a while. After some time (might be minutes or hours) the engine turns on and runs fine.
I have no clue what it might be, I believe it might be an electrical problem affecting the diesel pump. The pump has a pair of cables coming in to a white plug at the pump's back, I disconnected them but the engine still runs.
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my 2000 f350 7.3 is acting strange lately. Its got 252k and is all stock other than exhaust,intake,ww2. It smokes white every random once in a while for some reason. At start up it wont though. If i get on it every once in a while it will smoke white then go to back to black. Im not consuming coolant, and the oil looks fine, no residue on the oil cap and its not puffing out the oil cap either. Other than that its running great just dont know why it goes white every so often.
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The engine in my truck sometimes cuts out seems to be at idle. Takes a lot of cranking together going. Might be related but the electric fuel pump seems to run every time I turn the key on and if i sit with key off and the engine not going. I hear the pump come on again. No external leaks can be seen.
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I have a 2002 F250 7.3 4WD automatic with 313,000 miles. A week ago it started stalling after it idled for 10 minutes. It acted like it wasn't getting fuel. It would sputter a few times then just quit. I changed the fuel filter and the truck ran fine the rest of the day. Since that day, it has acted the same way every morning at 1st startup. It idles fine for 10-20 minutes (depending on how cold it is outside), then hesitates a little, then stops. After going through 3 new fuel filters (thinking I had bad fuel), I stopped putting in a new filter every morning, and found that if I just waited 4 or 5 minutes, it would start and run fine after that. It then runs fine the rest of the day.
After it stalls, it will not start right away. I need to wait a few minutes. I've tried draining the fuel filter bowl also. No luck. I tried a new Cam Positioning Sensor. It seems to be related to temperature. It's been getting down to 30 degrees Fahrenheit the past few mornings. It starts fine and idles fine until the temp gauge just starts to move. Then, the stall happens. My fill-up just prior to this happening was with B20 Bio Diesel. I suspected that for a while. But, I've ran all that fuel through plus 4 or 5 regular diesel tanks through, so I no longer think it was related to that. It do see the check engine light when it stalls. I had a shop read my codes and the only code was bad KAM memory. The mechanic said that code shows up all the time on these engines and not to worry about it.
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I got a 2000 f350 7.3. Cranks up fine runs fine put in reverse and can back up fine put it in drive and it bogs down and dies. What is causing that.
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1999 F350. It has the 7.3 diesel engine. His complaint is the truck will stall out on him shortly after filling up. It makes no difference if he is driving at full speed or stopped at a light the truck has stalled in both situations. He reports that he resulted to only filling up to half a tank for a while and that seemed to stop the problem. I was thinking a vent problem. Maybe the gas cap is bad causing a vacuum situation But I have read a few articles about tank delamination and now I'm not sure what to think.
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I have a 99 f350 7.3l 4x4 and my battery light flickers randomly. I have checked the alternator and both battery's. All brand new and seems to be ok. They only are getting a charge when the battery light is flickering. I put both new batteries in on Thursday and on Sunday I needed a jump at the store.
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I have a mostly stock '02 F-250.
The other day I parked the truck and as I was walking away I could hear what sounded like the 4x4 clicking on and off. I wasn't sure. I figured I would continue to run the truck to get more symptoms and come up with a diagnosis.
Later, backing out of the driveway, I heard what sounded like a buzzing/grinding noise, like something was trying to engage. It quickly went away.
The next day, the 4x4 light came on as I merged onto the interstate. I pulled over, tried switching the ESOF switch to get it to turn off. I never heard 4x4 engage or "felt" it. Re-starting the truck got the light to turn off. It hasn't been on since.
Today the truck made more buzzing/grinding noises. When I tried turning on 4 high with the ESOF switch I got no response. It went into 4 low and the light came on.
I re-started the truck. Tried putting it into 4 high again and the light came on. When I put it into 4 low the light quit and wouldn't come back on.
I run with my hubs unlocked and they were unlocked at the time, FYI. Also, I have air coming out of the vents, so no vacuum issues. I actually disconnected the 4x4 vacuum lines because I don't use the automatic locking future anyways.
I did do some work with my truck and boat during the flood in Louisiana and I took her through really sketchy stuff. My guess is that the ESOF motor is shot, most likely from being submerged.
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