I bought a 2002 F350. I noticed it had a Banks Big Hoss chip under the dash, but thought little of it since I don't know much about diesels. My mpgs have been steadily decreasing, and the pickup feels sluggish, so after 2 years I checked out the chip and the corner has been cut off; I was informed by someone in the know that the corner was cut to destroy the chip. I thought maybe a SuperChips tuner might erase the computer program and reprogramming it would fix it, but it didn't. How do I fix it. Any help would be appreciated, the pickup got 18 mpg on the highway when I bought it, and this 10 mpg ain't cutting it. Thank you.

 

Have you removed the chip?

 

I did take the chip out and the performance seemed to get worse. I was hauling a gooseneck trailer, total maybe 8200 gvw, and the mpg were 10 or worse and going up hills it was going 45 mph with the throttle mashed.

A fellow I talked to after pulling the chip said just pulling it wouldn't return to stock programming, and that I could either get Ford to flash the PCM or order another Banks module.

I thought maybe a SuperChips tuner could wipe the memory bugs from the damaged Banks module and reset a better program. I towed the same trailer yesterday and got 12 mpg, but anytime it would really start to pull it made a sound like spitting before down shifting. Every time it would pull hard the check engine light would come on. One time the PTC was something like "could communicate with control module" and another time the PTC was something like "ICP pressure undesirable."

 

I'd pull the super chip tune back out and sell that and look into gettin a custom 6 postion chip with the tunes you want. Super chips is a very weak tuner.

 

First, take your PCM out and sent it to a trusted tuner or ford to get it reflashed to stock. By removing the chip it should have removed the tuning from the PCM, but I have heard of ghost tunes being left behind by poor quality programmers/chips such as the Banks or Superchips.
Secondly, get gauges. Your going to burn up your engine and transmission if you havnt already by just mashing the throttle. If you are only reaching 45 that means that something is wrong, not push the skinny harder.
I would not expect more than 12 mpg pulling a trailer hard without custom tunes. Now if you were getting 12mpg unloaded, then there would be an issue to address, but there are too many variables now to consider to make a correct diagnosis.
In the meantime, check EBP sensor. It, and the tube leading to it is likely clogged with soot. Remove both and clean them using a carbon cleaner. Be very careful with the actual sensor and it might be better to just replace it.

---AutoMerged DoublePost---

Btw, this means that either you a weak HPOP, you have a bad ICP sensor, or you have poor quality tuning.
The last option is my guess.

 

I appreciate the posts so far. At the risk of sounding naive, I have to ask some questions; keep in mind this is my first diesel and my I'd say I have decent basic mechanic skills but I don't know what I'm looking at with this diesel. What gauges are necessary? A friend suggested a exhaust temp gauge, but said if I don't drive hard I should be fine. What is the EBP sensor and where is the tube that needs cleaned? I've been reading a lot about ICP sensors; a lot that I've been reading says sometimes the connections are bad. Is that an easy fix?

 

On the basis of the ICP, if you are leaking any oil of the connections, a replacement of the sensor and the connection should fix that problem. Forums are the best place to learn, and there are a lot of people on them that are very willing to help you out.
I suggest the common three gauges Boost, Tranny Temp, and EGT (pyrometer).
The EBP sensor is the Exhaust Back Pressure Sensor. Type it in to google and you will find lots of threads about it. Its located on the front of the block in front of the HPOP. Pretty easy to access and service with the right tools which you having some mechanic skills I would presume to have.