04 F350 6.0 noise and surge between 1700& 2000 rpms

David Cothren · April 18, 2005

F350 21,000 miles oil& filter change with fuel filters replaced. Customer drives 20 miles hooks to horse trailer goes 50 miles truck starts acting up. Check for DTCs one hard fault three memory for accel. pedal, replaced, no codes return. Truck has a fluttering type noise in intake and air filter box also surges. Only between 1700 & 2000 rpms on steady pull with or without trailer. Truck has manual trans., doesn't matter what gear. It's like turbo is working then shuts down real quick. It will do this 5 or 6 times real fast, almost like a buck and jerk. Again no codes, hotline says engineering is working on a fix for 04 & 05. Hotline also said it was normal at that rpm. It never done this for 21,000 miles, how could it be normal!!!!

Keith Browning · April 19, 2005

I think I read a few threads on the "other" web sites that sound exactly like this. This definitely sounds like one of those little problems that can only pop up after the vehicle is in service for a while. It really sounds like a pressure sensor going bad and the PCM is simply reacting to what it sees. Did the Hot Line engineer mention what they believe the root cause is? Did they have any further instructions or data they wanted you to collect?

Normal? I think we have all come to understand that the abnormal is normal for the six point oh! Perhaps a poor choice of words, I think "typical" or "common" is what they meant.

FordMastertech · April 19, 2005

4118 - 2004 F-SUPER DUTY/EXCURSION 6.0L BUILT AFTER 9/30/2003 - VARIOUS DRIVEABILITY CONCERNS

SOME 2004 F-SUPER DUTY AND EXCURSION VEHICLES BUILT AFTER 9/30/2003 WITH A 6.0L ENGINE MAY EXHIBIT ANY OF THE FOLLOWING: RPM SURGE AT IDLE; AUDIBLE EGR SURGE; LOW POWER/SMOKE/ROUGH IDLE FOLLOWING A COLD START THAT CORRECTS AFTER ENGINE IS WARM; SURGE ON RESUME WITH SPEED CONTROL; INTAKE FLUTTER SOUND AT STEADY STATE THROTTLE, JUST BEFORE DOWNSHIFT, ON AUTOMATIC TRANSMISSION VEHICLES; BUCK/JERK SURGE ON MANUAL TRANS VEHICLES. TO SERVICE, REPROGRAM THE PCM AND FICM TO THE LATEST CALIBRATION USING WDS RELEASE B36.10 AND HIGHER, OR B37.1 AND HIGHER. THIS NEW CALIBRATION IS NOT INCLUDED IN THE B37.0 CD. CALIBRATION FILES MAY ALSO BE OBTAINED AT http://WWW.MOTORCRAFT.COM. NOTE: THIS CALIBRATION ALSO REDUCES THE EGR ON-TIME DURING EXTENDED IDLE.

David Cothren · April 19, 2005

Keith, the first hotline guy said, tell the owner to change his driving habit! After 21,000 of doing fine, he said drop a gear and wind the rubber band tighter. He is not the one buying the fuel either. He tried to say it was normal under those conditions. He wasn't the one facing the customer with a $45,000 (plus) truck when those words where said. I didn't like and the customer sure wasn't happy. The second hotline guy told me about engineering working on an update. That was it!!

Keith Browning · April 27, 2005

18554 2004 F-SUPER DUTY/EXCURSION 6.0L BUILT AFTER 9/30/2003 - VARIOUS DRIVEABILITY CONCERNS

SOME 2004 F-SUPER DUTY AND EXCURSION VEHICLES BUILT AFTER 9/30/2003 WITH A 6.0L ENGINE MAY EXHIBIT ANY OF THE FOLLOWING: RPM SURGE AT IDLE; AUDIBLE EGR SURGE; LOW POWER/SMOKE/ROUGH IDLE FOLLOWING A COLD START THAT CORRECTS AFTER ENGINE IS WARM; SURGE ON RESUME WITH SPEED CONTROL; INTAKE FLUTTER SOUND AT STEADY STATE THROTTLE, JUST BEFORE DOWNSHIFT, ON AUTOMATIC TRANSMISSION VEHICLES; BUCK/JERK SURGE ON MANUAL TRANS VEHICLES. TO SERVICE, REPROGRAM THE PCM AND FICM TO THE LATEST CALIBRATION USING WDS RELEASE B36.10 AND HIGHER, OR B37.1 AND HIGHER. THIS NEW CALIBRATION IS NOT INCLUDED IN THE B37.0 CD. CALIBRATION FILES MAY ALSO BE OBTAINED AT http://WWW.MOTORCRAFT.COM. NOTE: THIS CALIBRATION ALSO REDUCES THE EGR ON-TIME DURING EXTENDED IDLE.

EFFECTIVE DATE: 04/18/2005

David Cothren · April 27, 2005

I just got my B37 update Monday, getting ready to call customer. Let you know how things go as soon as possible. Thanks!!!!

Keith Browning · April 27, 2005

Quote:

THIS NEW CALIBRATION IS NOT INCLUDED IN THE B37.0 CD.

You are going to have to update your WDS software and calibration files. I am also suspicious that you may have to manually download this calibration. If that is the case you will need to contact the Hot Line to get the file name. Either way, I would still contact the Hot Line to clarify this SSM.

David Cothren · May 6, 2005

Updated truck with 37.2 - something. When truck returned had code P0404, replaced sticking egr valve. Now the truck runs fine, customer wants me to tell hotline it is now back to normal. Bottom line is customer is happy, I'm happy that he is happy. Now it is own the next headache!! Thanks for the info. Have a good day and a better one tomorrow!!!!