6.0L Power Stroke Engine and DrivetrainDiscussion 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.
2004 6.0 F250 4WD. Truck surges all the time except at idle. Doesn't matter if cold or hot, pedal on floor or not this thing surges. It is very consistant and has caused mileage to go down to 11 mpg (My 04 King Ranch got 16.8).
Had 2 techs look at it, one diesel mech and other mech at stealership. Both hooked computers up and both say "I don't know". Both say "everything" is checking good ie: injectors, boost, all pressures etc. (Basically all electronics)
Dealer mech says oil temp a little high but ok. COULD NOT control EGR valve with computer. COULD control turbo and other things but not EGR valve. Said was opening and closing very erradict and can't figure out why. Changed EGR valve and NO difference, Unplugged it and NO difference. Changed fuel filters, NO difference. When I changed ER valve, fair amount of carbon in intake but nothing major. Had to clean valve once in the past due to large chunks of carbon holding valve open. Seems truck ran better back then (8 months ago) but has gradually gotten worse. I'm somewhat mechanically inclined but not to this extent. Both want me to leave it with them so they can "figure it out" but I don't have that kind of $$$$$$$$$$ Any suggestions??????????
2004 6.0 F250 4WD. Truck surges all the time except at idle. Doesn't matter if cold or hot, pedal on floor or not this thing surges. It is very consistant and has caused mileage to go down to 11 mpg (My 04 King Ranch got 16.8).
Had 2 techs look at it, one diesel mech and other mech at stealership. Both hooked computers up and both say "I don't know". Both say "everything" is checking good ie: injectors, boost, all pressures etc. (Basically all electronics)
Dealer mech says oil temp a little high but ok. COULD NOT control EGR valve with computer. COULD control turbo and other things but not EGR valve. Said was opening and closing very erradict and can't figure out why. Changed EGR valve and NO difference, Unplugged it and NO difference. Changed fuel filters, NO difference. When I changed ER valve, fair amount of carbon in intake but nothing major. Had to clean valve once in the past due to large chunks of carbon holding valve open. Seems truck ran better back then (8 months ago) but has gradually gotten worse. I'm somewhat mechanically inclined but not to this extent. Both want me to leave it with them so they can "figure it out" but I don't have that kind of $$$$$$$$$$ Any suggestions??????????
Most likley suspect to me is still the EGR valve. I'd replace it with a new one (not clean it), but I'd also do every thing I could to clean out the intake port it sits in. Another candidate is your oil - if its over full, it can froth up & cause a surging situation. Not as common as the EGR, but still can happen.
OMC
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Feb 03 6.0 Silver F-250 SD SC XLT long box, 6-spd 3.73ls, Fx4, Stock, Spray-in liner, Contico box.HARPOONED.
Did change valve. What's the best way to clean out the port where it sits. If I'm not mistaken that is the intake and it also connects to the EGR cooler and such. If the carbon is heavy is there a cleaner that can be sprayed in there without causing damage. If not, how do I clean it without taking everything apart and using a vat or something. If I go that far I'll just replace everything while I'm in there (EGR cooler, oil cooler). 6.0 is worst I've ever had, just wish my 02 7.3 was crew cab not extended.
This still sounds like an EGR system issue to me, which is controlled by a number of sensors. Were there any codes when they had the scanner hooked up? Are you sure the installed EGR valve is good. As I recall reading on here, there were some issues with valves manufactured last spring being bad. I doubt this anything to do with whatever soot is in your intake.
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2004 F-350 Lariat, Supercab 4X4 FX4, DRW
Dark Toreador Red/Silver, 6.0L, Torqueshift Auto, ESOF, 4.10 LS, Camper Package, Dual Alternators. Build Date 6-8-04, Eng 5-28-04, Lance 9.5 Ft Camper.
Valve was good but have ordered new one to make sure. No codes other than when I unplugged valve to see if it changed anything (no difference). Cleaned IAT#2 and no difference. Tech is stumped as well. And yes EGR valves were bad, told dealers to pull all on shelf. Was told to only use ones with pink dot and silver dot on top, this is newest valve.
Last edited by airpig95; 08-07-2008 at 12:07 AM.
Reason: Added more
I had a 2003 F350 that did the same thing to me. Ford tried numerous times to fix it but never got it right. I finally took Ford to arbirtration and won based on a safety issue covered under the 5yr 100,000 mile motor warrenty. Good luck.
My friends '04 had similar problem, but less consistent than yours. Recently he lost all power and for some reason they said it was his alternator. But in the meantime they found bad wiring in the main wiring harness. Rewired that at the same time as replacing alternator, runs the best it ever has. I saw somewhere that some of the '04's came with bad '03 engines and I believe there is a class action about that.
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2005 Arizona Beige F250 6.0PS automatic, MBRP 4" turbo back, AFE stage I, EGR delete, ARP studs, SCTx3, B&W turnover ball gooseneck with 5th wheel companion, Firestone airbags, Dipricol gauges, B&D exhaust brake, Bedrug and Snugtop SL tonneau cover, Zoodad mod, Blue spring upgrade, Sinister coolant filter.
this will sound retarded but check the oil level. if your even a couple quarts low it will run like a bag of crap. would explain high oil temp. im assuming you and the techtards checked this though...........
I had the same problem, I cleaned my EGR valve and it didn't change anything, I took it to a shop and he monitored the valve and it was opening and closing erratically also, so I had it completely changed. I had cleaned it a week before and when he pulled it, it looked like it had never been cleaned, turns out I had a cracked EGR cooler that was causing excessive soot buildup, so I had a EGR cooler delete put on. (if your building lots of soot quickly, I'd also pull and clean the MAP and boost sensors cause they are up stream from the EGR valve and will usually be clogged too)
I have a later model '04 F-250 that had two surge issues. One was a surge at idle when stopped at a stoplight or in traffic. Kinda scary, but just a quick surge and a drop back to normal. I replaced the IPC Sensor and it improved, then used contact cleaner on the connection between the sensor and the pigtail harness. That ends the surge for 3 - 4 weeks before it happens again, so I need to replace the pigtail harness for a better connection.
The other problem was a surge at midrange throttle. If I babied it, no surge and at full throttle, no surge. Anywhere in between it would surge constantly, going uphills, accelerating onto the freeway, etc. Very annoying, but not debilitating.
I figured it could be one of several things. TPS, EGR, VGT, Wiring Harness, or possibly even a fuel injector. I don't know of any trustworthy shops around here, but didn't want to just blindly throw parts at it either.
My troubleshooting:
1. Turned on cruise control and climbed hills. Still had the surge so figured NOT TPS.
2. From what I had read, it didn't sound exactly like other EGR problems, but wanted to eliminate it. So I unplugged EGR valve and drove around. No change in behavior, but the EGR had been replaced less than 10k miles earlier, so put it in the "most likely not the problem category."
3. VGT: Did the relearn procedure on my existing part to see if it would help. No change. It also didn't do any of the "learning" that you're supposed to hear during the procedure. So, I'm pretty sure this is the troublemaker, but not positive.
4. Injector. Figured...more like hoping actually...that this was only an outside chance.
So, found the part number for the VGT and searched online. Prices ranged from $240 to $350. I decided to ponder options a bit more. Then, by chance, a VGT turned up on eBay. New, unopened in box for $180. So I gambled on it.
It arrived today, I installed it, did the "relearn" procedure and took it out for a drive. NO SURGE!! Problem solved for $180 plus $10 shipping.
One thing I did notice about the two solenoids is that the New one has a tiny circular screen over the oil intake that was missing from my original. I don't know if it never had one or if it fell off somehow, but it's something to look for. If I can figure out how to attach pics that show what I'm talking about, I will.
Anyway, thought the above might be helpful to someone.
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Surging---all The Time
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