Ford Super Duty (1999-2016) :: 2002 F350 7.3L - Rough Idle / Knocking / Loss Of Power


Aug 10, 2017

Alright, I have a 2002 f350 7.3 4x4 ext cab xlt with 300k miles. Bought in may 2016 with 260k miles and towards November started running rough and felt like a loss of power. Had a no start but a new gray cps fixed that issue. Running fine. About a week later started it up and it had a rough idle, felt like not all cylinders/injectors were working. Was "knocking" and a loss of power. I was in the army at the time and stationed in Georgia, took it to a local diesel shop in Georgia and they confirmed my icp sensor was bad and injector #1 , #5 #7 were bad. Work was busy and money was scarce so I left it as it is and was saving up to buy the new parts. Then one day approx a week after the visit to the shop, I started the truck up and it ran fine. No misfire no knock no rough idle, drove fine for about a month.

In December, I was on vacation in florida to see my parents, drove the truck down, ran fine. While on vacation one day in a Walmart parking lot the truck didn't start up. Couldn't fix any issues then so towed the truck to my parents house. Did more troubleshoot, replaced fuel filter, cps, ipr valve, icp sensor, glow plugs, glow plug relay, ebpv pedestal was replaced with a ebpv delete pedestal. All parts bought oem and/or from riffraff diesel. Still would not start up. So then I bought a refurbished IDM from eBay, oem and then the truck finally started up one day but running rough again like it used to, then it wouldn't start again. So then, I replaced the PCM with a reflashed/refurbished one off eBay and boom truck started up, still running rough but now it starts up every time.

Now, took all eight injectors out and replaced all the o rings. Cleaned them up and put them back in, truck still running rough. Injectors didn't appear damaged nor the wiring harness so now I bought three reman injectors from riffraff. And replaced those three bad injectors. One of them is not spitting oil out the oil spout on the injector.

My dad has worked on freightliner semi trucks for years and is fairly knowledgeable when it comes to diesels. However he did something very amateurish the other day. So two injectors were installed while we were still waiting on the third in the mail. He wanted to see how the engine reacts when that one bad injector was not in play, but instead of unplugging the injector under the valve cover, he cut the wire outside the valve cover to the injector. He stated it's not a big deal and he can solder the wires back together. But once he cut the wire, the truck sounded a lot stronger, still rough idle but definitely stronger. Before, you would be pedal to the floor and the truck barely moves forward but now the truck will lunge forward. A big difference in power.

Now today, third injector came, swapped them out and fired up truck. We didn't solder the wire yet just quick connect, same you would use to connect wires for a car stereo. The new injector was not spitting oil out the oil spout. Even at high rev and truck warmed up. Truck still runs better with that one injector unplugged.

Tomorrow we will troubleshoot if somehow there's wires that grounding out or burnt out somewhere but as of right now everything seems to be in order, the uvch are tight, and no signs of anything burnt.

Triple checked everything, still getting fuel pressure, still getting oil pressure what gives? I also replaced the MAP sensor. Fuel pump is fine, fuel gets to fuel bowl. The next thing I'm thinking is maybe the hpop but we have oil pressure so idk..

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Ford Super Duty (1999-2016) :: Loss Of Power And Rough Idle

Last night, I left it running while unloading a trailer and come back to notice it was idling abnormal. I jumped in it and tried to move it and there was a noticeable loss of power. I unhooked the trailer and tried to get it home. I only made it 1/2 mile down the road when it started spitting and sputtering (surging ever now and then) to a level that it died completely. I was able to start it back and get it out of the road but had to be pulled into a drive. It got to a point it wouldn't start back at all.

Today it started up however still had a rough idle and really has no power to speak of. The more I messed with it the less power it seem to have.

I have searched the forums and tried these things:

1) Checked the oil and noticed it was on the low end of the operating range. I put some in it to put it back to normal.
2) Disconnected the ICP
3) Changed the crankshaft position sensor
4) I dumped the fuel bowl after it completely died (in case it had any water in the fuel bowl).

The fuel filter was just changed 2 weeks ago. The fuel pump seems to be operating correctly (or it at least refilled the bowl) and started again with a very rough idle.

It doesn't have a engine light on nor do I have anything to read any codes it may be showing.

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All symptoms typically disappear over 1k rpm so I have limited idle time and manipulated engine speed to try and maintain 1000-1200 and all has been well for past 36k miles. Today noise (valve clatter?) persisted at all rpm and during a scramble to get off the highway all oil pressure was lost (I'm aware that pressure gauge on dash is not 100% reliable). After total pressure loss I cut engine and called tow truck. Out of curiosity, I actuated ignition and motor cranked maybe two rotations, and then appeared seized. After about 45 min waiting for tow I went back to disengage 4wd and take my rifles and skis out of truck. At this time I actuated ignition again and engine fired and ran as it had for past 36k miles. I drove about one mile constantly watching oil pressure gauge, then noise returned followed by instant drop from normal to 0 pressure (dash gauge) I immediately shut of engine.

I am a mechanical engineer, but not a mechanic. I am familiar with the cam phaser system and I understand that their operation is directly related to oil pressure. Today's temp was under 0'F. I have a very skilled mechanic who works for around 30-40% of cost of licensed shop and I know his skills to be on par.

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there is no check engine light. its been doing this on and off for a week. i dont drive it much, may 15 miles a day. i thought maybe it was bad gas , i had it sitting for a month, but since then ran almost 2 tanks of gas through it. Seems to act the worst when driving it, then letting it idle for 5 mins, then drive it again, that's when its very noticeable. no smoke from exhaust, no mixing of oil and anti freeze, plugs are a year old, filter is new.

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Ford Super Duty (1999-2016) :: 2003 F350 - Power Loss / Runs Only Up To 30 MPH

2003 F350 6.0L ... 171,000 miles ... 5,100 since oil change 15W-30 at the shop ...

I was driving on the interstate (50 miles of driving) struggling to maintain 70-75 mph at 2,200RPMs. I would accelerate and RPMs would go up to 3,000 but no speed. Before I could pull off speed slowed to 50 before dying. Sat on the side of the road 30 minutes before I could get it started. Had to give it gas. No misfires just quietly started. Couldn't go over 30 mph. Towed it to my destination 135 miles.

Volts on 7Pin FICM read fine.
Checked the fuel fulters. Air Filter. Tank for debris. Nothing.

My coolant reservoir was lose and I noticed a lot of coolant in the driverside front wheel well and down the left side of the undertruck. Reattached after checking FICM. Hope that was all it was cause I couldn't find any leaks.

I had Planned to have the oil changed before the return trip before this all happened. New to Diesel engines but I like a challenge. Where do I go next?

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Ford Super Duty (1999-2016) :: 1999 F350 V10 - Loss Of Power / No Acceleration Over 2500 RPMs

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If you drive the truck normally like a grandmother it seems to be ok. As long as you dont need a passing gear or need to accelerate more than 1/4 pedal

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