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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 12-17-2012, 06:33 PM   #1 (permalink)
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help stuck in the mountains

04 F350 6.0. I am up in the mountains away from my tool box and most importantly away from my scan tool. A few weeks ago I changed the ICP sensor which cured the run problems I had. the truck has been running fine but on the trip up the fuel economy was horrible, used half a tank used to make the trip on a quarter. It has been running fine until we decided to go into town about an hour ago. The truck started fine and initially ran fine I got half way off of the parking deck and the injectors started rattling a lot worse than normal and the truck died. I tried starting it and it wanted to light just not quite. After 4 or 5 tries it lit but had a worse than normal injector rattle and was running on 4 or 5 cylinders. I held the throttle at about 1800 which is where it ran the best until it warmed up hoping that it might straighen out. It didn't. It will start and run now but if you put it in gear you can floor it and it will barely move. Any ideas what I might look for with the limited tools I have at my disposal??
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Old 12-17-2012, 06:40 PM   #2 (permalink)
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04 F350 6.0. I am up in the mountains away from my tool box and most importantly away from my scan tool. A few weeks ago I changed the ICP sensor which cured the run problems I had. the truck has been running fine but on the trip up the fuel economy was horrible, used half a tank used to make the trip on a quarter. It has been running fine until we decided to go into town about an hour ago. The truck started fine and initially ran fine I got half way off of the parking deck and the injectors started rattling a lot worse than normal and the truck died. I tried starting it and it wanted to light just not quite. After 4 or 5 tries it lit but had a worse than normal injector rattle and was running on 4 or 5 cylinders. I held the throttle at about 1800 which is where it ran the best until it warmed up hoping that it might straighen out. It didn't. It will start and run now but if you put it in gear you can floor it and it will barely move. Any ideas what I might look for with the limited tools I have at my disposal??

Fuel gelling maybe...plugged or dirty filters. Sounds like a fueling issue
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Old 12-17-2012, 06:49 PM   #3 (permalink)
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check batt volts and ficm. whats the outside temp?
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Old 12-17-2012, 07:25 PM   #4 (permalink)
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The temp right now is probably in the 40's About two thousand miles ago I changed to synthetic oil and changed the fuel filter with oem. You say filters plural, is there a fuel filter somewhere that I am missing? Only had the truck for about a year and a half.
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Old 12-17-2012, 07:41 PM   #5 (permalink)
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you have two fuel filters. One is probably very plugged by now ............

The primary fuel filter is part of the fuel pump - in what is called the HFCM - located on the driver's side frame rail.

If you bought an OEM fuel filter it would have come in a box with TWO filters ...........
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Old 12-17-2012, 07:48 PM   #6 (permalink)
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Isn't Motorcraft Fords OEM brand name? Only came with one filter,
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Old 12-17-2012, 07:50 PM   #7 (permalink)
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To my knowledge Ford has NEVER sold a single fuel filter - always sold in pairs. I would sure like to see a part number on what you were sold.

Regardless, you have a filter to change ...........
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Old 12-17-2012, 08:21 PM   #8 (permalink)
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Doesn,t matter I have someone coming up to rescue us. I will be coming up later in the week with the small tool box and the scan tool. Hopefully It is not too complicated a repair and I can get this thing running again. I am not convinced that it is a fuel filter problem but I will be bringing both up with me. The way this happened it was like someone flipped a switch. It wasn't gradual like I would suspect with a fuel filter. one second it was running fine the next second the injectors started rattling and the engine died.
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Old 12-17-2012, 08:25 PM   #9 (permalink)
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Low fuel pressure will damage injectors .........
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Old 12-17-2012, 08:47 PM   #10 (permalink)
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This seems to me to be EGR valve related.
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Old 12-17-2012, 08:52 PM   #11 (permalink)
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FYI, FD-4616 is the Motorcraft fuel filter number. Has Frame rail and engine filter. O'reilly (Schucks) carries them. Just hapen to buy it today.
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Old 12-17-2012, 09:00 PM   #12 (permalink)
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I would guess the frame mounted one is plugged! It is the primary one that does most of the work. Which one did you replace..likely the easy under the hood...
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Old 12-17-2012, 09:49 PM   #13 (permalink)
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This seems to me to be EGR valve related.
I have not heard of an EGR valve causing excessive injector "rattling". I suppose anything is possible though.
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Last edited by bismic; 12-17-2012 at 09:52 PM.
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Old 12-18-2012, 07:31 AM   #14 (permalink)
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I don't like to diagnose without physically seeing the vehicle, but it sounds like you lost your high pressure oil system. That could be your IPR valve, high pressure oil pump, base engine oil pump not filling the reservoir, cut o-ring. The list goes on and on.

First thing to check though is your oil level.
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Old 12-18-2012, 09:45 AM   #15 (permalink)
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Thanks to all for the responses, I was hoping that there might have been something I could do to get it down the mountain but alas no. A friend came up and rescued us (was a great get away) the truck is still on the parking deck. I did talk to a friend of a friend that recently retired from Cal Trans and now works for some kind of outfit that has a fleet of these things. When I described to him the complete scenario, which did include black smoke when I finally got it re started don't believe that I mentioned that, his opinion was that the black smoke would indicate too much fuel as opposed to too little. His best guess, because the problem was so sudden, is that something decided to pop in the FICM. I am going back this weekend with scan tool dvom etc. in hand to pull codes. I am guessing that will reveal a lot more than any speculation. At this point all I am interested in is getting it running well enough to get me to a Chevy dealership. In 50 years of driving this is the first vehicle that has ever stranded me to the point that I could not patch it and get home, and I will not drive something that I can not trust. I love everything about this truck but the parts between the firewall and the front bumper. With all apologies to those of you who still love your Ford, back in the days when I made a living as an auto mechainc I had a co worker that used to tell me to quit complaining about Henry, if it wasn't for him you might be unemployed. Guess I should have listened.
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