Help 2004 6.0 Surging - Diesel Forum

mortarmagotjoe · 07-22-2009, 11:58 PM

I'm having trouble with my 2004 F250, with the 6.0 in it surging. I have the truck at the dealership right now and they are pretty much idiots. Unless the computer tells them what is wrong they have no idea. It all started several months ago. My truck would surge when at an idle or going down the road between 30 and 40 mph. I have already changed the fuel filters, cleaned the EGR, had an EGR test run and it passed, had the programing reflashed, and had a flush done on the manifold to remove carbon build up. My truck still surges when at idle or sitting at a stop sign or light. I have almost rear ended someone on more than one occassion because of this problem. My Ford dealer is no real help. I even resorted to calling Ford directly but they just take a statement and say my dealer will call me which they never did. I am at my witts end with this truck. Can anyone out there please give me some insight on what might be wrong. Thank you.

gillettebeanz · 07-23-2009, 12:11 AM

ICP sensor???

mortarmagotjoe · 07-23-2009, 08:15 AM

What is the ICP sensor? Still kind of new to all this. Thanks.

bgoux · 07-23-2009, 10:37 AM

I dont Know if it will help but...
I have had exactly that problem for about 2 years now, Been thru the EGR, ICP,systems,oil level and aeriation, multiple times at dealer, however I am not allowed to speak to tech face to face, only thru service rep,
I Have found that pulling the IAT2 sensor and cleaning it with brake cleaner spray will suspend the surging for a week or two in conjuntion with cleaning egr valve,( I dont think that cleaning the EGR valve is the solution)
there is a small cage on the bottom of the sensor that fills with carbon/debris and seems to help for a short time, every attempt seems to help for a short time, but it always returns,
the dealer has been great as far as trying to find the problem, but it seems to be a problem that they cannot pinpoint, and is only intermittent, unless of course you drive it everyday, my warranty just ended so I am frustrated enough to start throwing parts at it , as wrong as it might be, it seems that it is the last resort
I have considered contacting Gofasterdammit since he is within my range and seems to understand these machines better than most, but that solution is extreme as well
I can list the loooooong version of what I have been thru if you are interested but it doesn't have any happy ending yet
BTW I just had the EGR/ OIL cooler full slam with all the tests and diagnostics, low and behold 2 weeks later it is back....... if I find a solution I will post it

bgoux · 07-23-2009, 10:43 AM

ooops sorry
ICP sensor is,
Injection control pressure sensor, in pass side valve cover front or for early model 04 under turbo
I have had 3 no help but RO says it tested faulty

jdroste · 07-23-2009, 01:45 PM

Have them check the Injectors. My 6.0 was doing the same thing except for at idle. Turned out I had a bad injector. Finally after my suggestion to the dealership on the 3rd attempt. The found the issue and replaced. solved the problem.

mortarmagotjoe · 07-23-2009, 08:53 PM

Quote:

Originally Posted by bgoux

I dont Know if it will help but...
I have had exactly that problem for about 2 years now, Been thru the EGR, ICP,systems,oil level and aeriation, multiple times at dealer, however I am not allowed to speak to tech face to face, only thru service rep,
I Have found that pulling the IAT2 sensor and cleaning it with brake cleaner spray will suspend the surging for a week or two in conjuntion with cleaning egr valve,( I dont think that cleaning the EGR valve is the solution)
there is a small cage on the bottom of the sensor that fills with carbon/debris and seems to help for a short time, every attempt seems to help for a short time, but it always returns,
the dealer has been great as far as trying to find the problem, but it seems to be a problem that they cannot pinpoint, and is only intermittent, unless of course you drive it everyday, my warranty just ended so I am frustrated enough to start throwing parts at it , as wrong as it might be, it seems that it is the last resort
I have considered contacting Gofasterdammit since he is within my range and seems to understand these machines better than most, but that solution is extreme as well
I can list the loooooong version of what I have been thru if you are interested but it doesn't have any happy ending yet
BTW I just had the EGR/ OIL cooler full slam with all the tests and diagnostics, low and behold 2 weeks later it is back....... if I find a solution I will post it

I know what you are saying. I just found out this morning my EGR cooler failed and put oil into my coolant system. And low and behold, the BS warranty they sold me with my truck. Not Coverd. 1900 bucks to fix. I'm ready to put a foot up the dealers you know what. I'll bet anything it will still surge when i get it back too. Sounds like we are having the same problems. Could be your throttle sensor on your gas pedal too. Since that is all electronic now. I will keep you informed. should get my truck back next weeks some time.

AdrienCarden · 07-24-2009, 12:34 AM

Have a same problem with me 04. know excatly what my problem is after going threw the same heart ach. I'm sure you have had your EBP sensor pig tail replaced by warrenty by now. My truck surges and turbo farts all the time and it's the pig tail for the EBP sensor not being properly connected. First time it happened the pig tail had a small hole wore in the wire. This grounded it out. Which in affect, causes the EGR not to work and the EBP not to send the proper signal to the EGR valve. And so on and so on. Sucks but, you should get a new pig tail and see if your not just getting a EBP sensor circuit error signal code. If so, you need a new pig tail ($60) they are gold plated/ get it re-sotered. Or your EBP sensor could be fouled out. Try and see if this works. After you do all this disconnect your batteries for 10 mins or so. Then drive to the speed of 45 for a couple of mins coast down (no brakes) to the speed of 20, then back to 65 for a couple of mins then down to 45 (no brakes). Now just drive normal and hit your brakes. That will run most of the ECU checks on your truck.

TRAILORDUNE · 07-24-2009, 12:40 AM

Don't know if this will help but my 04 had the surge at idle off an on basically since new. Dealer could not fix until I went in for headgaskets 6 months ago and it has not surged at all since then. The one thing they replaced that sparked my interest was the IPR valve that the tech said the screen was sucked in backwards so he replaced it. This is my best guess on the surge problem as I previously tried everything I could, oil level, brand etc. Good luck.

bgoux · 07-25-2009, 06:00 PM

WOW
That many different causes for the same symptom,
my IAT2 senser, injectors, egr valves, ebp sensers and a IPR valve!

To any techs that read this, is it possible for all these to show the same symtom? IE surging idle?

**bigblue** · 07-25-2009, 07:52 PM

Interesting. I have a minor "idle surge" while at a stop - a hundred or two rpm - enough for me to say "what the f..." and sometimes I think I can feel it at speed. I will have to roll up my sleeves and take a look at the suggestions above.

rooster46 · 07-26-2009, 09:31 PM

Never heard of the EBP sensor pigtail warranty. Ford had a recall that reflashed system to ignore EBP as I understand it. I have had this done, but I also have a supposed turbo fart issue too, but no surge. I am curious to hear more on this pigtail deal. I am still trying to diagnose fart. Many people say it is veins sticking. But I am not yet convinced because of the irregularity of the farting. Changed EGR valve & that did not help. Unplugged MAP & it did stop. But I hear that the PCM goes to default & veins are not moving. Truck seemes to run just fine though. Now checking if MAP is good or bad. I have an 04 F-350 built in June of 03.

**bigblue** · 07-27-2009, 09:13 AM

Veins and farts. Sounds like a cholesterol problem.

catzndogz22 · 07-28-2009, 06:07 PM

My '03 is doing the exact same thing and it scares the wits out of me. Last week, while idling at a red light, it surged then died, but started right up again. I took it to the shop and they replaced the ICP sensor and IPR valve for a whopping $800, but the problem hasn't gone away.

mortarmagotjoe · 07-29-2009, 12:18 AM

Well it sounds like a Ford Dealer for you. Just throw a bunch of parts at it, at your expense.

Mine is in the shop for a surge, never died...yet..... Anyway, they told me the EGR cooler went out and put oil into my coolant, so have to replace EGR cooler and all the hoses and have the system flushed. Anyway, when they called to tell me said the bill would be around $1900 bucks, i'm sure that didn't include the diagnostic fees and taxes. But I will bet you that 1900 that i will still have a surging problem when i get it back. I'm thinking about putting the EGR Delete kit on it. Just heard of another guy in NE having the same problems with his. Ford needs to step up to the plate and acknowlage they have a problem and get to the bottom of it.

Has anyone had contact with Ford about this issue? If I rear end someone or get into an accident because of this issue, I will sue the hell out of Ford Motor Company for not stepping up and dealing with their problems. If your with me I want to hear from you. Let's all get together and be a thorn in Ford's side.

Joe