Ford 6.0L Power Stroke Diesel :: 2004 - Rough Idle - No Power?


Apr 11, 2017

I recently bought a 2004 6.0 extended cab truck. It has 223,000 miles on it and has been running great. Bought it here in Arkansas where I live and recently drove it to Texas and back after having just put some Hot Shot oil treatment cleaner in it. I ran it the 1000 miles as it suggests. Just the other day as it was hitting the 1000 mile mark the truck started to lunge/runaway and stalled. I finally got it back home and started looking into the issue. Based on what it was doing, (lunging/running away, and at idle in park random burst of rpms and then dying after doing it a few times), I started to do some research. Most of the answers I found claimed it was the IPR valve. I found that the IPR valve is supposed to, as claimed by some, be pulled and inspected every 100,000 miles are so and if need be replaced or the rebuild kit gotten for it. So I decided to just replace it as well as the oil, oil filter and fuel filters.

When replacing the IPR valve I noticed that it was original and that its screen was missing. I didn't have any problem moving the little piston in the center of the shaft with a small bolt however that doesn't really mean that it isn't bad. I tried a magnet to see if the screen was still in there and nothing came out. I did not try using a camera as I do not currently have one, to look inside the port to see if I saw it. After replacing the IPR valve with a brand new one and changing the oil I started the truck. It seemed to be running a little ruff so I let it warm up. Not one minute later the exact same thing started happening, lunging/running away (random increase and decrease in rpms), so I called it a night. The next morning I decided to change the fuel filters. No that it matters the order in which I did it, but I changed the top end filter first and the the one on the frame with the dealer recommended OEM filters as was the case with the oil. I did find in the filter on the frame that there was a small amount of sand and clay soil looking matter in the filter. I did clean out the filter housing as well.

After replacing the filters I started the truck to warm it up. I noticed that it was still running a little ruff but no random, lunging/running away (random increase and decrease in rpms). However after five minutes it started coming back. I finished letting the truck warm up and took it for a drive. Got it up to between 7-80mph for about 15 miles to try and see if I could "blow out" whatever may be in the fuel if that was even an issue I do not know. The truck seemed to get more power and run a little more smoothly so I stopped at my buddies house not to far from where I was and let it idle. No issues other than a little ruff idle. After about 10min I took off towards home doing similar speeds. I noticed at a little over 2000rpms that the truck was shaking a little but so I dropped the speed down. When I got home not more than one min after idling the same issue, lunging/running away (random increase and decrease in rpms), started happening again.

At this point I took back to the interwebs and came across a post that said the ICP might be bad and does cause this issue, lunging/running away (random increase and decrease in rpms). However I also noticed that this is a huge debate as to whether or not the ICP can cause this. Ford master mechanics say no and other mechanics say yes and round and round it goes. I decided to do the simple test many recommended which was to simply unplug the ICP and see if anything changes. Things did change. No more lunging/running away (random increase and decrease in rpms). Not more than two minutes after plugging it back in, allowing the computer to account for it now, the lunging/running away (random increase and decrease in rpms) came back. In the middle of it doing this I unplugged it and that went away. So needless to say I replaced the ICP and voila the lunging/running away (random increase and decrease in rpms) is gone but the ruff idle is still there along with a slight loss of power.

To answer some questions:

1. The oil and water are not mixing so I am almost positive that the heads are fine

2. The intercooler couplings are leaking a bit. I have ordered the new ones and will replace them as soon as they come in. Can this cause the issue?

3. I am blowing no white or black smoke except for when the lunging/running away (random increase and decrease in rpms) issue was present and the truck almost died. It would knock occasionally when it almost died and would send a slight puff of black smoke which I assume is a low or high fuel issue from the truck trying to die

4. I have not had the no start issue at all

5. I did not see any debris in the oil during the oil change

6. I didn't do the air test on the ICP port as I do not have the adapter.

7. The only code I got on the IBD II port was when I unplugged the ICP which was to be expected

8. I found no damaged wires

I am at the point where I am wanting to take it to ford to have them run a diagnostic on it but am wondering if there is anything else I need to be looking for. Here are a few questions I have.

1. Does this sound like a bad injector? (When I bought the truck it would sound like a misfire or ruff idle condition was present for about 5-15 seconds and then it would smooth out with no issues. It would run a little ruff if you tried to take off without letting it warm up, which I did once or twice and low rpms, but when it warmed up no issues were present).

2. Could this be the HPOP?

3. Could this be the FCIM? (The previous owner had replaced the FCIM not to long ago with one from Ford I believe. Said it cost him something like $700)

4. Could this be something clogging the oil screen under the manifold?

My final question right now is do any of you know where or what brand OBD II reader or software I can get for a decent price that will tell me the voltage of each injector and FCIM is without me having to go to Ford to get it looked at.

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If that doesn't work, I'll replace the two injectors. How does that sound.

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With my scangauge hooked up I checked out the ICV values (which appear to be good .25 before startup .84 at idle) ICP (22% at idle 48% at 3-4k rpms) and FICM Voltage (47.5v consistently).

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Here's a video of startup : [URL] ....

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To get you up to speed. for a few weeks before had intermittent trouble starting. would fire up as normal, fast and loud, but then stall immediately (usually after sitting overnight). would start back up but with a little long on the key and some gas pedal action. only happen one out of ten or twenty starts and seemed to follow getting fuel in unknown locations while on a trip out of town. decided to change out fuel filters and drain separator. seemed to fix it for a week or so then it happened again two days before above event, while weather was dry. Not sure if related but only recent problem to speak of.

Back to current:
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