I have a 2004 f250 4x4 6.0 with a 6 speed manual tranny. It has an amsoil bypass oil filtration kit(runnin 5w30 hdd) and amsoil cone air filter in a modified stock air box and is also straight piped with 4" with cat and muffler delete. Other than that it is bone stock.
Problem:
When I start it sometimes it will fire up and idle around 250 rpm or lower and shake the whole truck for about 3 sec. tops then it will kick up to 750 rpm and be fine. Sometimes it will also act like its going to start then dies. It dosent do this all the time and temperature dosent seem to play a factor. I have no smoke (white, blue, or black) ever. I am stumped. I had a diesel tech put on the scan tool and run tests on it and it threw a couple codes. One was egr but the previous owner had just cleaned it before I bought it and the other code had him thinkin cam sensor. So I replaced the cam sensor and the crank sensor and it still does it. I NEED HELP! Thanks in advance.

 

The crankshaft position sensor and the camshaft position sensor almost never go bad on these, and when they do, they typically both don't go at the same time. Usually they get falsely thrown as codes when the truck is cranked a lot trying to start or re-start. If you have EGR codes, then you have EGR problems. It probably needs cleaning again, they don't stay clean forever. A full delete would be best, if you live in a state that you can do so.

Test your FICM. 6.0's, FICM's and Cold Start Problems - PowerStrokeNation

 

Ive been tossin around the idea of doin the delete kit. Ive heard sinister is good but what about the other kits? I saw this one EGR Delete Kit, Ford Powerstroke 6.0 F250 F350 F450 | eBay and this one FORD 6.0L 2003-07 EGR DELETE KIT F450-F550 Exscursion | eBay . I actually was trying to check the egr on saturday and couldnt get it out. Is there a trick to getting it outta there? I will also test the FICM as well and let u know the results.

 

the egr valve has just the two screws holding it down. It is kind of a bear pulling it out even after the bolts are out. Make sure to unplug, then I usually gently pry it up with a flat head or something of the sort. Dont pry too hard or u can marr up the intake surface it sits on. Probably want to do it when the vehicle is cold also. Good Luck You can check the voltage of the ficm but from what i understand is that even if the voltage is good, it doesnt mean that there is nothing wrong with it still.

 

I couldn't get mine out either, and I was using a full pry bar. Luckily I was swapping intake manifolds when I did it, so it didn't matter, just pulled the whole intake out... egr valve still stuck in it too.

 

Thats awesome! Not! I thought I was just bein a pu$$y. What do you think about those egr delete kits I posted up? They look like they come with the same stuff as sinister just at half or better of the price. I was really looking into doin the egr delete anyways, just got to convince the wife that im not just buyin more toys for my trucks. Prolly check the FICM this weekend if not earlier as well.

 

That EGR kit looks exactly like my River City Diesel kit I paid $185 shipped for... I'd go for it.

 

Alright, good deal! I went ahead and put an offer on it. Offered 120. Ima cheap ba$tard! If they dont except it I will prolly just go ahead and pay askin price.

 

Yeah, doesn't hurt.

If you really want to be a cheap-****, you can go buy a couple freeze plugs, or get some stainless plate and cut it to fit into the opening and exit of your stock EGR cooler. Weld the plates in, replace the cooler and wha-la, no more exhaust gases entering the egr cooler. Even it explodes internally, all that happens is it fills up with coolant. That's all! It's about a $2 and a 12 pack mod.

 

Haha! Ive seen people do that. I would but thats were my cheap azzness draws the line. I weld in all but im a little cautious with messin around with a truck thats motor is prolly worth more than any of my other trucks ive owned combined. Havent checked ebay lately to see if they accepted my offer yet. Would love to get this by the weekend and get er on there to see if it helps me out any.

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Got the egr valve out last night. If the guy had cleaned it right before I bought it then Ive got a pretty dirty truck. Cleaned it all up and have had 2 good starts in a row. See if it keeps starting good then that must have been the problem. Heres pics of it.


after i cleaned it the best i could