I just had a ton of work done on my '04 F350. It started with sludge in degas bottle took it to shop and was told the oil cooler was shot. Since they had to go in there to do all that I just went ahead and had some bullet proof done since I was going to do it anyways.

I had the head studs done, new stock oil cooler, bullet proof egr cooler(which was deleted), and a few other odd and end items. Once I got it back started to notice some other issues come up. The mechanic that did the work has been real helpful to get truck back up and running for me at no extra charge "for price I paid shouldn't be charged, and shouldn't have to bring it back". Well he ended up having to change out the oil sending unit that was changed very poorly. And throwing codes still for egr cooler and #5 glow plug. There is also a banks inter cooler installed on the truck which was there when I purchased. Come to find out it is for a '07 and who ever did it had to remove more of the smog equipment that is under the intercooler "which I found behind the back seat."

I towed my toyhauler up to the mountains for some riding, truck ran great until we got into town and had a surge in the idle at a stop light, then at next one it was just idleing and then just died, but started right back up. Made it to where we were going with no other problems after that. We also made it back home with little problems other then a couple surges at stop lights. Next day after getting home I was taking quads to storage and the truck lacked power, a few times while driving would just surge on rpms and once it also started to run rough when slowing to a stop. We first noticed at sold start the truck would idle real rough and at warm no problems at all. Last thing not sure if related, but the lights on stock stereo went out and then wife was driving in evening and noticed when head lights were on that the lights on dash went out. I recently put in some reconditioned batteries, times are tough right now for new ones.

Any ideas of what to look at would be very helpful. Going to dump this thing off at mechanic also to have him repull codes. I haven't even owned this truck a year and havent had it back a couple weeks from all the work. Also calling dealership I purchased from since all smog equipment was gone and I live in Ca.

 

Sounds like the mechanic didn't get all the electrical cnnectors plugged in all the way, check around the right side fenderwell area for the connectors coming from the motor. the surging is normally associated from a bad ICP sensor, make sure it is a Ford part, the aftermarket ones have had some issues. Look at the extra parts you have, is there even a butterfly valv in it? early 04s don't have it and all the parts are dummys, not even contacts in them for connectors. the late 04s do have the elec conn.

 

If I remember right there is no butterfly valve in it. There is a connector that is suppose to goto one of the parts that is removed. When doing the delete kit are they suppose to use programmer and set it up not throw the code for egr? Once wife gets back with truck I'll go back out and check around for the connectors and I have been reading up on the ICP sensor.

 

if it does not have the butterfly valve then it is a "dummy set" no electrical pins in it. On the 04 trucks you won't get a CEL light but it will throw a soft code. they use the MAS sensor and the intake iar temp sensor to figure out egr flow.

 

I'm getting a CEL, friend is bringing over a reader to pull the codes then will look them up. Thanks for the reply will see how it all works out.