Hi everyone. First posting so sorry if I break any rules but I will try not to.
Have had my 2004 excursion with PSD FOR close to 3 years now did regular maint. Oil every 5k with rotella t6 changed filter cap every 15k just for good measure. Fuel filters every 10k. Never had an issue until this past winter when I had an injector #8 and rick fail same time. Knowing what I know now FICM WAS probably failing for awhile, as it was a hard start below +30℉ to the point it would take two crank sessions to start and then smoke like crazy for the first couple minutes. I took care of both issues and had no additional problems until the one I am still dealing with. Which was around 2k miles later. I had the tip of my #1 injector break off while driving. Not knowing severity right away I mistakingly drove it home around 35 miles in that condition. The injector tip had damaged the piston and two valves which I thought was pretty lucky. Lucky in the fact the cylinder walls had not been damaged. Unfortunately like most people I didn't have money laying around to pay a specialist to do the work I would be setting out to do. After a couple weeks of research I decided that I would hop this excursion up a little bit. The list of new parts involved coolant filter, bypass oil filtration, new oil cooler, new turbo feed and drain lines ford oem parts, arp head studs, egr delete kit, oem head gaskets, one new oem piston, powermaxx turbo, industrial inj. 175cc, sct livewire ts for monitoring new parts and tune for all this stuff to work together, regulated return lines, air dog fuel pump, that's all I can remember right now. Just to let you know it has 3.5 down pipe and 4 in exhaust no kitty. Well had it all done bolted back together brought it up to temp 3 times drained coolant each time and oil after first run to operating temp, all this done before attempting to test drive. So now that I was ready for test drive I tried.... No power falling on it's sad bent a push rod. Replaced all with new oem push rods. Started again still no power. Found up pipe leaks to turbo adjusted the pipes leaks fixed. Used smoke machine on intake at same time no leaks at 13 psi . Killed batteries trying to figure it out got two new batteries and started idled fine but would die in gear. No boost pressure which I suspect must have been going on the whole time. Currently have turbo sent in to get warranted and "preliminary reports are suspecting oil starvation". Now my question how can this be as it has been idled to operating temp numerous times and injectors run on the oil pressure. Please someone smarter then me explain. I just want my Excursion running again and thought I took necessary steps to make it "bulletproof" and never have an issue again.

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For those wondering I did at home in garage cab on no hoist no lift. I amcertified technician by trade but not diesel.

 

That sux bro. How many miles on the injector pump and injectors. Fuel filter causing injector problems. why are you bending push rods? Timing?
is the Valve lash bad. Do you 6.0 guys have hydraulic lifters or tappets.

 

Zero miles on fuel pump hpop has 99xxx injectors brand new went bigger. Was told 90%+ of the time when tip breaks it is due to airation in fuel either by low fuel level or poor pump. That's why went with air dog. apparently if you don't set crankshaft to the 6 o clock position before doing heads it'll bend at least one everytime.

 

I have heard that about the Ford when the fuel is low that the motor will run away before it dies and it can damage the injectors. I cant believe your doing all this work in frame. that blows man. Do you have the FOMOCO manual for your truck. I mean run a Dodge and that is my best tool. until you Mod. then you go with the aftermarket specification. But still you will need all the process info and other stuff for your truck. best 85 dollars ive spent on it so far. Sounds like you are very close. and I read that the 6.0 is really good after the stuff you're doing but still no joy on the fuel economy like the Cummins but still a good puller and reliable.