Ford Super Duty (1999-2016) :: 2003 F350 - Hard Or No Start / Shaking In Low RPMs / Slow Response From Gas Pedal


Aug 22, 2016

I need fixing my 2003 f350 6.0 diesel, I have been working on this truck for a while and still am having problems, here was the original symptoms:

-Hard start or no start on a sunny day
-Rough idle for 10-15 minutes
-Rough shaking in the low RPMs (35 mph)[/COLOR]
-Slow response from the gas pedal
-boost would only get to 14

My dad and I then did many things to the truck in the shop, those things are:

-Air test and replacement of coupling going into oil branches (next to HPOP)
-Replaced EGR valve (no good)
-Replaced ICP sensor (leaking oil)
-Replaced ICP sensor and IPR valve piggtails (due to frayed wires)
-Cleaned Turbo
-Cut MAP sensor hose and reattached it (spliced on the end)
-New battery
-Performed a bubble test and found two bad injectors on passenger side (injectors #5 and #7)
-Cleaned and lubed tops of injectors
-Replaced O rings and copper crush washers on all injectors
-Replaced nipple cup O rings (tight)
-Blew out injector cups
-Bubble tested after injectors put back in (no more bubbles)
-New FICM, EGR cooler and oil cooler were already installed
-Ohm'd main engine wiring harness (good to go)
-Taped up frayed wires on fan clutch connection
-Increased wire gauge on the positive jumper between both batteries
-Sanded each ground on the batteries and engine, cleaned battery clamps, lithium greased connection points.
-Checked fuel for air (no air)
-Checked fuel psi (85 psi, plenty)
-Oil changed

After doing all of this (diagnosing as we fixed each thing) we now fixed many things including the hard/no start problem. Now, for the first three to five minutes:

-It starts right up
-Runs perfectly, no shake and instant response from the gas pedal and turbo
-Boost goes to 28
-ICP is 800-950 on idle
-IPR is 25-26.9% closed
After five minutes however:
-Starts to shake
-IPR % starts to raise
-Received no response from gas pedal (absolutely no power)

This truck has been torn apart like 8 times and I have to do it on my spare time.

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Ford Super Duty (1999-2016) :: 2003 - Pedal Would Sometimes Lose All Response And No Gauges

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Been an ongoing problem with truck, pedal would sometimes lose all response. truck starts and idles fine but will not throttle up and all needles on the instrument cluster are at their rested position and the odometer doesn't even light up, however all the backlights still work fine.

The owner said that a 10 amp fuse on the bottom row of the fuse panel would occasionally blow, and that's when the pedal would go dead, he would replace it and keep driving till it blew again... usually about a week. I checked all fuses on the truck tonight and all are fine.

Unplugged the connector on the pedal sensor and cleaned and reinstalled and still wont throttle up. I am not sure what number the fuse was that he kept replacing but i *think* it was a cluster fuse. Is their an correlation between the cluster stopping the pedal sensor from working or vice versa?

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