I just swapped in a 6.0 into my 03 the new is a 05. The engine came complete with harness, turbo evan altenator. I swapped the 03 harness on new engine installed in truck. It idled great went to drive it and no power at all. Figured it to be the icp sensor swapped that with the 03 sensor and it ran a little better. So then i swapped the plug for the icp again a little bit better. Put the old icp sensor back on and walla perfect! So than I installed edge and drove around for a couple of days got off work to day and problems are coming back ! Im stumped any suggestions on where to go next?

Here are some numbers I pulled from truck today from snap on solus:
Icp voltage = .26
Icp pressure = 425 kpa- Key on, 4500 kpa-idle

 

I see you posted on PSN too, you'll get more responses over there. I didn't think you could even interchange the engine years. I was told NOT to do this when a buddy with an 04 was looking for a motor, we found a clean 05 and were told it wouldn't work. Or that maybe it would work but be more trouble than it was worth. Please let us know how you make out.

 

I didnt post on psn only on here. It depends on the eigth digit of the vin mine is a p code the engine i have is the same. The guy that got the motor for me does swaps all the time.
Today I unhooked the edge and it ran great until it warmed up than it started missing again.

 

Well the 03/04 trucks have different injectors than the 05+ trucks, so I don't see how you can swap the injector harness' around.

Sorry, thought I read this on PSN. I would go ask it over there too, a lot more Ford tech people there.

www.powerstrokenation.com and you'll probably get an answer a lot faster!

 

Well maybe thats my problem im going to search and see what I can find out.
Thanks

 

I'm about to deal with the same thing.

What did you "swap"? There are 3 things I know that are at least 3 things different. (I'm sure there are more)

1- Intake (and EGR cooler), exhaust manifolds are different. But I'm told they can bolt from one to the other.
2- ICP is in different location.
3- EGR Position Sensor (Or something like that) Located under the elbow to the throttle body. I think '03 was the last to have that.

If you get it worked out please let me know the important information I need to know before I get a used motor.

I'll keep an eye out on PSN too.

 

03 and early 04 had that intake elbow with the butterfly in it, you can remove it and put an 05+ intake elbow on no issues.

Intake manifold is different, turbo/turbo pedistal, pistons, injectors, oil rails, Hpop, FICM (though they're interchangable), heads, I'm sure a lot more, just rattling these off the top of my head.

 

I swapped the whole wiring harness from the 03 to the 05 everything plugged in except the icp sensor which i rewired to work. you do need to swap the egr throttle valve and intake elbow which you are correct just bolts right up. The 05 intake and exhaust stayed on the engine. also the motor mounts make sure they are the same mine were different and had to swap them out after i had the motor in the truck!!! there are little things that are different but it pretty straight forward once you do it. The swap wasnt bad i did it at work it took me about 4 days to do it but that was still helping customers and answering the phone.

The problems im having are not due to the swap because the truck ran great for about 4 to 5 days and I have read that many 05 into 03 swaps have been done. Just make sure the 8th digit of your vin matches that of the vehical the engine is removed from.

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Injectors are the same and should work. I talked to a guy that did a swap just like mine and he said he did the exact samething and he had no trouble at all. I'm pulling my hair out on this one. Im getting the feeling though its something im overlooking. I checked fuel presure 50 psi key on and 48 to 50 under load. the truck idles perfect but it just wont GO it just spits and sputters and smokes!!!!

 

did you take care of some of the most common issues with the 05 before you dropped it in

#1- High pressure oil pump fitting/ sct fitting?/ this causes a no or hard start when hot or if it is bad enough it will run bad all the time

#2- egr valve, it will act like you are describing, if it is all crudded up and stuck it won't do much more than idle, I would check that first

as far as the icp sensor I think they are different because of the location, pres might be different

 

Ok I changed the sct fitting, and the ipr also did an egr delete. Put it all together and got a no start. Stumped I swapped out other icp sensor to the 03 and it start but runs like it did before so for now I'm going to order a new icp and try it.