Randomly stalling early build '04 f350

deezul · October 6, 2010

I have an early build 2004 f350 with the complaint of stalling, rough running and hard to re-start when stalled...

This truck came to me three months ago with similar complaints. Code p0341 was present. I replaced the cam sensor and then scoped the signal, the pattern was good with no issues present. I returned the truck to the customer and all was well.

Well...this week the truck has stalled twice on the customer. The only code present is p0299. Cannot duplicate stalling and/or rough running. It's idle is a bit more harsh than a comparable unit but it does still perform well without any noticeable issues...

Power balance shows no signs of issues, relative compression has 0% across all cylinders, EGR test passed, fuel pressure is at 105-110psi, crankcase pressures good as well.

Inspected harness, wiggled harness, inspected ICP and IPR connectors and sensors. Checked for harness wear under FICM...

Monitored the usual pids and cannot come up with anything..

I have read other posts relating to my issue but still come up with dead ends..

I have captured some screen shots of the PIDS at idle and at 1170RPM (or whatever the max command is for RPM) for shits to see if someone can see something I may be possibly missing.

Any help would be great! Thanks in advance...

A link to photobucket pics:

http://s892.photobucket.com/albums/ac128/auto_union/Powerstroke%20Issues/

Keith Browning · October 6, 2010

May I recommend that you install a VDR in the truck and drive it or send the customer back out and make a recording when it stalls and when it won't start?

Fuel pressure is a wee bit high dontcha think?

mchan68 · October 6, 2010

Power balance shows no signs of issues, relative compression has 0% across all cylinders, EGR test passed, fuel pressure is at 105-110psi, crankcase pressures good as well.

Inspected harness, wiggled harness, inspected ICP and IPR connectors and sensors. Checked for harness wear under FICM...

Monitored the usual pids and cannot come up with anything..

105 to 110 psi is WAYYYY too high. Either you have a fuel pressure regulator stuck closed or your gauge is not reading right. The spec is 56 psi at idle, and no less than 45 psi under load if I recall correctly, with the original pressure regulator. If it has the updated style with the blue spring I believe pressure at idle is bumped up to 65 psi. I think maximum pressure is somewhere around 75 psi before there is harm to be done to the injectors if I recall right.

Just to clarify, this IS an early build 2004 (with a 2003 engine and ICP sensor under the turbo) correct? The reason I ask is because I notice your ICP pressure at idle is 580 psi, and I also notice you have an EBP_A PID. If I'm not mistaken, 2003 engines usually idle at around 620 psi and EBP is missing in action (due to inferred EBP strategy).

deezul · October 6, 2010

Two things I buggered up:

1) I should have mentioned pressure was taken at HFCM, pressure at secondary filter was around 60psi...

2) The icp sensor isnt located under the back of the turbo so this engine IS NOT an early build (door tag said third month)...

LARRY BRUDZYNSKI · October 6, 2010

How many miles/km's on this truck?

Mikill · October 6, 2010

Two things I buggered up:

1) I should have mentioned pressure was taken at HFCM, pressure at secondary filter was around 60psi...

2) The icp sensor isnt located under the back of the turbo so this engine IS NOT an early build (door tag said third month)...

Even at the HFCM I don't believe I have ever seen the pressure above a 100 psi. I have seen a biased ICP sensor intermittently cause stalling concerns. I have also seen dummy plug o-rings that are not completely blown cause intermittent stalling. Cam sensor wiring has been known to have intermittent opens with no codes present.

deezul · October 6, 2010

Im going to install a VDR and let the customer take the truck back, the only way I can really figure out whats going on...

Keith Browning · October 6, 2010

Im going to install a VDR and let the customer take the truck back, the only way I can really figure out whats going on...

Posted Image

It's not necessarily the only way but it is a very logical approach.

Mekanik · October 8, 2010

How much fuel is in the tank when this happens? Does it happen after a hard accel? I ran into one like this a long time ago, where the orange bypass plug in the fuel pick up (in the tank)was missing, and it would take a big gulp of air on hard accel, as the fuel would move to the back of the fuel tank. It would always start out as a miss and then die. Then have a hard time starting due to the air in the fuel system.