2004 6.0 cutting out
 

Hello,
New to Diesels about 5 months.

I have a problem with my 2004 6.0, cutting out or like a miss on gas engine.
So far as long as I drive truck normal, no problems.

When towing a trailer two times, it runs good until stop, shut off engine.
Then when crank again it has a miss or cut out for a few minutes.

I've only had this happen while towing. The second time the "Service Engine Soon" light came on. Both times the fuel was from different stations and brands.
Banks 6 Gun set on #3.

Any suggestions?
Injector?

Thanks,
Walt

how is your boost

I don't know at this time, no gauge.
I have EGT & Boost gauges coming in a few days.

The first time it happened, I had pulled a flat bed trailer with some pallets of grass for about 20 miles at 55 mph or less.

Second, was pulling travel trailer of about 6000 lbs.

Thanks,
Walt

Ok, this weekend it did it again.
While towing, EGT's are about 1000 going to 1100-1200 temp. at hills.
After unloading trailer and cranked to move truck is when it started missing and then stop, then start again, at that time at idle, the EGT needle was fluctuating instead of being steady, even if not missing.
Today, not towing, ran fine, EGT needle was steady.

The Banks gauges plug into the Six Gun harness so I got to thinking it may be the Banks box overheating ?
I guess I will have to unplug the Banks to see if it will run correct.

I was going to purchase the AutoXRay scanner but it will not work with Diesels per their tech man.

Anyone using a hand held scanner with Diesels ? What kind ?

Any suggestions?

have you changed your fuel filters lately or cleaned the egr valve. just a few places to start.

Not sure exactly when filters or egr was cleaned.
I have only put 2500 miles on truck since I bought it. I am supposed to be about 1000 miles from changing all filters and oil per the previous owner of every 5000 miles.

I drained to see if water was in fuel but was clean of water, but did have some trash come out. My son has truck on vacation for another week and will change all when he returns. I'll check to see what I need to do with the EGR valve.

Thanks for the info.

my truck started doing that and i had a bad fuel injection controll modular plus my egr cooler was leaking and the injector harness was bad cost about $3000 to get it fixed thank god for a warranty

Sounds like a VGT sticking or an EGR valve issue.

Sorry about late reply. Computer has been in the shop.

Thanks for the heads up ideas.
I have changed oil and fuel filters. I'll have to try towing again to see if still does it.
As I drained the separator before removing filter, some minute trash drained out.
I have not been on the road yet.

Again thanks.
Walt

Don't rule out the Six gun i had one in my truck and the connection was rusty inside causing it to do the same thing that you are talking about. The one i had only did it when i washed it the day before or heavy rain outside. Just something to check for free.

when my truck was doing that it ended up being 2 injectors were bad. one wasn't firing at all and the other was firing intermittantly.

Sorry about late response.
Thanks for the info.
I thought it could be the Six Gun.
I am going to get it scanned again for codes this week after all codes were reset and pulled trailer again. Then I may unplug the Six Gun to see if that helps. I only run the Six Gun on #3 setting. Boost/exhaust temps are Ok.

I changed oil & filter along with the fuel filters. There was some trash in the filter drain when draining the fuel to change filter on frame.
I drove about 30 miles Thursday not towing and it did an intermittent cut out a couple of times.

I'll have to put in the shop to get it checked.

I was looking at buying the new AutoXray 7000 Scanner but they told me it did not work with diesels.

What Scanner are you all using to run injector balance checks, real time recording, datalogging to see what is happening?

Thanks again,

Walt

Ford IDS

It's only about 8-12 grand, depending on what options you order it with.

Is the ICP sensor in the valve cover on the passenger side, or underneath the turbo? After thinking about this - this could also be the concern - they leak oil and it mucks up the readings to the PCM and sends it all goofy.

I'll check it tomorrow.

I've not had this truck long enough (2500 miles) to know if it uses oil.
It did not use oil in those 2500 miles. I just changed it. Truck has 95,000 miles.

Thanks.
Walt

It doesn't leak oil bad enough to leave a puddle, or give you a noticeable loss of oil between oil changes, but it leaks bad enough to screw around with your ICP readings, and cause a loss of signal between the sensor pins and pigtail connector.

Is the ICP under the turbo? If it is, you'll be able to look up on the driver's side up behind the exhaust feed pipe - there will be a little foil covered boot over the ICP sensor and connector, and it'll likely be soaked in oil.

Will cause all sorts of wacky driveability concerns, and seldom turn the CEL on.

Thanks,
I did not get to work on it today. I'll try tomorrow and let you know.
I assume it is as you say under the turbo.

The engine and under the hood is very clean.

Walt

Look on the passenger side valve cover. If the wiring from the glow plug control module plugs face the firewall, there should be an ICP sensor right beside it.

If the glow plug control module plugs face the passenger's side fender and kind of point towards the ground (Remember - it's mounted to the valve cover, so it won't be level.) the ICP is likely under the turbo.

I don't have any pics handy of early/late build trucks. I can get some tomorrow if it would be of any help.

The basic part number of the ICP sensor is 9H838 (prefix and suffix will vary dependent on early/late build), and the pigtail harness part number is 5C3Z-12224-A (fairly pricey though - but on the upside, the terminals are gold plated!)

The ICP is in the passenger side valve cover and wiring connection is clean and dry.
I had it scanned for codes and only came up with 0299. Cleared and it came up again.
I think that is caused from the exhaust pressure sensor. Supposedly Ford found it was more trouble and reflashed to eliminate it being checked.
Engine was too hot to try to look at it tonight so will look for the leak tomorrow but that is not the cause of the intermittent roughness I don't think.
Mechanic also said to plug the EGR pipes to eliminate it.
I'll look at the IPR for any oilness too.


Thanks,
Walt

I would monitor the ICP voltage KOEO, and see if it's flopping around a bit, even though the sensor looks OK.

If you have a P0299, it can be caused by a lot of different things, but the most common causes are EBP sensor, EGR valve, and the VGT portion of the turbo being seized up.

Or even charge air cooler system leaks - cracked intercooler tubes, rock hole in the intercooler, etc, etc.

Thanks,
I will check it this weekend.
Yes, it is the 0299 code, I had it cleared and immediately showed again. That code is supposed to be eliminated by reflashing the computer from what I have been told. So it really is not telling anything I guess.

When it cuts out, the EGT gauge needle will drop at the same time.
The EGT and Boost gauges are Banks and plug into the Six Gun. I guess I will get a new set of gauges so I can disconnect the Six Gun. I will search for a data program so I can monitor it. I can't justify $8k for the Ford type.

I have looked at the AutoEnginuity program and supposedly will work with Diesels.
If there are others better, I would appreciate knowing.

Walt

Update.
Thanks for replies.

Got the Boost and EGT gauges in.
Boost and EGT is ok.
Fuel and Oil filters changed.
No oil leaking.
ICP is on valve cover not under turbo.
No engine check light.


I bought the AE program to scan codes.

I got a P2285 for the ICP Sensor Circuit Low volt.
Cleared the codes.

I moved the wires and plugs to see if bad connection for the Banks and computer plugs.
The P2285 did not show again.

My son made a 250 mile trip, NOT TOWING Trailer, and he said he did not feel the miss at all. But I checked for codes when he returned and it has a P1378 for FICM low voltage and B1352 for Ignition Key-in Circuit Failure.

Does this mean to replace the FICM or ICP sensor or another underlying problem to cause this?
If replaced, how do you program the FICM, Dealer only?

And the B1352 problem?

Thanks,
Walt