6.0 Power Stroke Ford smokes and hesitates bad on acceleration

[sibleyson]

I been trying to come up with something on a sick Powerstroke 6.0 in a 04 F-250. I am a well trained auto tech but am not that great with diesels. This truck will idle all day but sputters and hesitates under a load so bad it wont even pull itself Also the cloud of white smoke out the tailpipe is pretty rich smelling. Already replced the fuel pump thinking that was it. Just happened all of a sudden. Does anyone have any ideas? tHANKS

[ryanv75]

I am not a mechanic, but have seen two 6.0ls and a 5.9 cummins all have blown injectors. Sounds like you have the classic symptoms. Loss of power and unburnt fuel coming out the exhaust. Very common with 2003s and 2004s.

[SMOKESKULL]

Any DTCs detected? Hace you tested fuel pressure? Is there any air in the secondary filter housing? Like after its been running and you loosen the cap does it hisss out air? I saw a truck without a copper gasket on the bottom of the injector that was alowwing compression into the fuel system.

[EVtech]

I think I would check the E.G.R.valve before you go any further. Remove the valve and see if its stuck open with soot and carbon, it doesn't have to be stuck open much to cause a problem. You'll see 2 valves on a common shaft,you shouldn't be able to see daylight between the valves and the seats. I've found that ordinary "purple cleaner"cleans them pretty good, but don't submerge the elec. part, just the the lower part that gets black. Hope it helps.

[_Diesel]

Does the turbo spool up?

[acausey]

Sounds like mine when the EGR was clogged with carbon rocks - except mine was smoking black not white.

[broome101]

where is the EGR value at what doe sit look like, mne did same thing today then it stopped after I let it sit little bit.

[Roosterq]

The EGR valve is right on top of the engine right next to the oil filter. It is about the size of a can of tomato sauce. It is held on by 2 8mm bolts. Remove the bolts and plug and pop out the valve.

[kman780]

I would look at the boost tubes too, maybe a boot is blown off or something simple like that.

[Ironwolfe]

Originally Posted by sibleyson

I been trying to come up with something on a sick Powerstroke 6.0 in a 04 F-250. I am a well trained auto tech but am not that great with diesels. This truck will idle all day but sputters and hesitates under a load so bad it wont even pull itself Also the cloud of white smoke out the tailpipe is pretty rich smelling. Already replced the fuel pump thinking that was it. Just happened all of a sudden. Does anyone have any ideas? tHANKS

Did you ever figure out what was wrong with your truck? I have a 06 thats doing the samething!! Any info would be app. Thanks

[05 Excursion]

Hello this is my first day on here. I have a 05 Excursion runs good then stumbles alot once I am on the highway and up to speed. Then when I am in the city and try to leave from a stop light the truck wont go white smoke and then black smoke and away it goes like nothing is wrong. Any Ideas?????????? The check engine light is now on and tells me its #5 glow plug is not working. I have also found lots of reports about the FICM messing up and I have the diagrams to repair the soilder problems. I will also check that EGR tonight, change the Glow Plugs and Re-soilder the FICM. Hope this works.

[05 Excursion]

I also bought a 5" exhaust for the beast and going to customize and install it tomorrow. When I start the beast in the morning I have a bad rattle sometimes and it sounds like its coming from the cat. Has anyone had to get there cat changed and if so what kind of issues were you having?????

[ex mounty]

Originally Posted by 05 Excursion

Hello this is my first day on here. I have a 05 Excursion runs good then stumbles alot once I am on the highway and up to speed. Then when I am in the city and try to leave from a stop light the truck wont go white smoke and then black smoke and away it goes like nothing is wrong. Any Ideas?????????? The check engine light is now on and tells me its #5 glow plug is not working. I have also found lots of reports about the FICM messing up and I have the diagrams to repair the soilder problems. I will also check that EGR tonight, change the Glow Plugs and Re-soilder the FICM. Hope this works.

Don't assume anything.
To properly check your FICM requires that you remove the batteries from the truck, bring them somewhere to have them LOAD tested. If they fail, replace them.
The second step in checking your FICM is to charge the batteries fully. Do not assume that because the truck turns over rapidly that the batteries are charged. VERIFY that they are by putting each on a battery charger.
The third step in properly checking your FICM is to click on the following link and following the directions to the letter.
If your FICM fails the check after properly preparing for it, and you have supreme soldering skills, follow the repair procedure. If your soldering skills are anything like mine (seriously lacking any skill), do not attempt to repair it yourself. The reason I say that is if you were to attempt repairs, and fail, then decide to send your FICM to someone along the lines of SWAMPS, they will not refund your "core" charge. They would have to fix the repair you attempted, then repair the FICM.

Next, I highly recommend that you install a set of gauges, NOW. The link in my signature line, "Basic Info" will explain to you the gauges you need, why you need them and what to watch for.
I suspect that your "white smoke" could be steam, and, if I am correct, you are flirting with disaster every time you crank the engine over. Cylinders 5 and 7 typically see some strange things happening just before your head gaskets fail. The coolant could be building up in those cylinders while your truck is parked, and that could be why the glowplug in that cylinder is throwing a code.
Theres a long explanation for all this, but your oil cooler clogs, that slows the coolant flow to the EGR cooler and the EGR cooler overheats and then it fails internally. That failure allows coolant to flow into the exhaust stream. When the EGR valve opens, it sucks that coolant into the intake manifold and down into the cylinders. When the EGR valve is closed, the coolant is flowing out of the EGR cooler the opposite direction, and enters the exhaust stream through the passenger side up-pipe, then goes through the turbo, then exits the truck through the exhaust system. Sometimes, under low throttle conditions, this can present itself as steam out the exhaust.
When you switch the engine off, the coolant, being under pressure, will still flow out into the exhaust, into the passenger side up-pipe. BUT now that there is no airflow to force the coolant flow upwards to the turbo, it will flow into the passenger side exhaust manifold, and should an exhaust valve be open, it will fill that cylinder with coolant. This is why I say that every time you turn the truck over, you are flirting with disaster.
This is what I think could be happening. Theres a reason why your truck is smoking, find that reason. Do not ignore it or it will cost much much more in the long run.

[05 Excursion]

Had to replace #6 Glow plug and I cleaned out my EGR valve and now check engine lights is out. It was still bucking and farting a only at highway speeds in overdrive. Removed the cat and found it was pluged up big time could not see any light through it. I now have much better acceleration response and only alittle bit of bucking and farting now. Doing the FICM test tonight and my soldering skills are top notch if I need to do the repair. I also had another code which was Fuel pressure switch but its not coming up anymore either. I am going to do a fuel pressure system check and hope for the best. I hope its not the fuel pump, it looks a little scary with the size of the 180L fuel tank.

[teamroper60]

Originally Posted by 05 Excursion

I also had another code which was Fuel pressure switch but its not coming up anymore either. I am going to do a fuel pressure system check and hope for the best. I hope its not the fuel pump, it looks a little scary with the size of the 180L fuel tank.

There is no fuel pressure switch. You have apparently misread that code. Do you know what number it was? You will need a mechanical gauge to test fuel pressure.

BTW, the fuel pump is on the frame rail, not in the tank and changing a pump is not as daunting a task as you might think. You will take a diesel bath to do it but it isn't all that difficult.