Help 2004 6.0 Surging

[catzndogz22]

Good point. I worry more about running over a little kid at an intersection. I suspect Ford won't do anything about it until there's actual damage or injury, but at least if we let them know, it takes away their excuse that they weren't aware of the issue.

[Strokin' 6.0]

I don't have a surging issue, but I do have the EGR cooler leak like you. I bought my EGR "permanent fix" kit from River City Diesel, and it's getting installed on Monday, along with a catalytic converter "permanent fix". The whole EGR cooler design is just piss-poor.

Take your truck to a different dealer, or an independant mechanic who knows what he's doing. My warranty didn't cover the EGR system either, which is why I opted for the "permanent fix" solution.

Good luck.

[crusincrew]

Took my truck in yesterday for same issues, surging idle, truck bucking at highway speeds, stalling and occassional rev up while in traffic. This condition started about a couple of months ago and left. Came back this Monday and got real bad Tuesday morning. Dealer called this afternoon to explain that I have excessive coking (carbon build-up) in the: egr valve (to be replaced, turbo inlet tube (to be soaked & cleaned), turbo (rebuilt new internals) and finally intake (soaked & cleaned). Out of pocket expense with extended warranty $1450.00 approximately for labor. Because coking is a maintainence issue Ford won't cover the bill for labor but will for parts. Does this sound right, the coking thing?

[mortarmagotjoe]

Originally Posted by crusincrew

Took my truck in yesterday for same issues, surging idle, truck bucking at highway speeds, stalling and occassional rev up while in traffic. This condition started about a couple of months ago and left. Came back this Monday and got real bad Tuesday morning. Dealer called this afternoon to explain that I have excessive coking (carbon build-up) in the: egr valve (to be replaced, turbo inlet tube (to be soaked & cleaned), turbo (rebuilt new internals) and finally intake (soaked & cleaned). Out of pocket expense with extended warranty $1450.00 approximately for labor. Because coking is a maintainence issue Ford won't cover the bill for labor but will for parts. Does this sound right, the coking thing?

Not sure. I know when I took mine in last time before the oil cooler they hit me up for 450 bucks to do a carbon flush of the system because there was carbon build up on the manifold. I didn't have any rebuild on the turbo, probably needs it though. That will probably be down the road. Those extended warranty are a bunch of jokes. I will never waste the money again on them.

I did call ford about this issue. They would not give many any technical assistance. They just referred me back to my dealer where i had my truck serviced. Told me I would be hearing from them within 3 days. I never did hear a thing from them. Big surprise. And when I talked to the service manager this last time and they said that Ford has no record of this issue on their online stuff. I told them that was BS and they should give them a call. So far. Since my EGR Oil Cooler has been replaced I haven't had any issues. But it's only been a couple days.

[mortarmagotjoe]

Originally Posted by Strokin' 6.0

I don't have a surging issue, but I do have the EGR cooler leak like you. I bought my EGR "permanent fix" kit from River City Diesel, and it's getting installed on Monday, along with a catalytic converter "permanent fix". The whole EGR cooler design is just piss-poor.

Take your truck to a different dealer, or an independant mechanic who knows what he's doing. My warranty didn't cover the EGR system either, which is why I opted for the "permanent fix" solution.

Good luck.

Strokin

What did your EGR Fix kit run you and cost to install? Also the Catalytic converter fix?

[Strokin' 6.0]

Joe, the EGR "fix" was around four hundred something...I'm at work, so I don't have the receipt with me..the install is $450 at my local mechanic. He's charging me $150 to "fix" the cat. The cat shell will still be there, it will just be "fixed" for good.

[AdrienCarden]

The warrenty actually had something to do with replacing the whole wire harness, but not all trucks needed this done only some. The ones that didn't need it had pigtails replaced with some new sensors added. 04's

[servoD]

I had the exact same problem! Took it to the dealer many times. Replaced every sensor there was. Connected the diagnostics for a week while I drove it. They couldn't figure it out and as a last desperate attempt they replaced the wiring harnesses. I haven't had a bit of trouble since!
I almost rear-ended a couple of cars when this first happened. When I was at a stop light I would put both feet on the brake in case it surged! I was scary!
Have them replace the wiring harnesses in the engine, specifically the one on the left side as you're standing in front of the truck. The mechanic used a cable tie to keep it up off the hot engine.
I had this problem for months. And it's fixed!

[mfalvarez]

I had the same problem with surging. I took it to the dealer and they diagnosed it with blown a head gasket. The service manager told me that this is a common problem with this engine. They replace about 25 to 30 head gaskets along with EGR Coolers and Oil Cooler kits per month. Since my truck is already out of warranty, I am paying out of pocket on this. The disappointment is that my truck has 151,000 miles and has this type of major problem. A diesel engine should not have a catastrophic failure like this with this mileage. I have owned much smaller gas engines that did not have such problems with the same mileage. I would expect this type of problem at around 500,000 with a diesel engine.

[ford_doctor]

Originally Posted by mortarmagotjoe

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.

An ICP sensor concern will cause RPM surging and at any speed. Usually it is at random and can vary as far as intensity is concerned. The sensor itself may be the problem however poor connections due to the sensor connector will also cause erratic RPM changes. Being a 2004 model I question if this truck is an early build with a 2003 level engine that has the ICP sensor mounted on the High Pressure Oil Pump (HPOP). THe ICP sensors on those engines have a high failure rate. Typically the sensors literally come apart causing erratic signals AND they leak engine oil. The oil not only makes a mess but it also ends up in the harness requiring replacement of the sensor harness connector.

If your surging is more noticable at cruise I might suspect a turbocharger issue, specifically with the unison ring that controls the vanes. A worn control lever slot will cause a cyclic surging under light throttle and stready throttle operations.

To be honest, it can be difficult sometimes to diagnose a customer's concern depending on the frequency and and severity of the problem. A simple data recording made during a road test will usually pick up something like this provided the truck exhibits the concern.

[mortarmagotjoe]

Originally Posted by Strokin' 6.0

Joe, the EGR "fix" was around four hundred something...I'm at work, so I don't have the receipt with me..the install is $450 at my local mechanic. He's charging me $150 to "fix" the cat. The cat shell will still be there, it will just be "fixed" for good.

Strokin'

Did they have to clear any codes after the Cat Fix? Or are all the sensors before the Cat? Was just wondering. Thinking about doing the same to mine.

[mortarmagotjoe]

Well since my oil cooler was replaced i haven't had any issues with it surging. I just find it funny how it took me two trips to the dealership for them to figure it out. What did that head gasket run you out of pocket?

[fordstang93]

I have a 2004 6.0 with 63,000 miles with idle surging only noticeable at idle. Normal idle is 650-660 range. When the surging occurs it will drop down to 619 then jump up to 690. it fluctuates through those ranges and is audible when listening and I can some times feeling the cab shake when there is a big jump in RPMs. took in and was diagnoced as ICP sensor. they replaced ICP and i still had problems. They then pointed to my Edge Attiude w/Juice. I took off, had edge reflash and it passed all their tests. Put edge back on and Drove from Santa Barbara to Malibu(90-100 miles) for work and had idle issues again. Took off edge unit again. Drove to same trip again 4 days later without edge and had same idle issue. Back at dealership again!

Getting rid of edge attitude any way and getting SCT X3 and edge insight monitor w/EGT prob.

[FK000@aol.com]

HAD THE SAME problem ICP sensor.............

[Strokin' 6.0]

Originally Posted by mortarmagotjoe

Strokin'

Did they have to clear any codes after the Cat Fix? Or are all the sensors before the Cat? Was just wondering. Thinking about doing the same to mine.

Joe,

Didn't get the cat "fixed" this time around...budget didn't allow it...it'll get done next month. If you check out my last post on the "EGR Cooler Out Twice In Six Months" thread, I did a write-up on what was done.

FWIW, the truck didn't set off any CELs, after the EGR cooler was "fixed", and it runs great now.