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Old 03-04-2013, 07:11 PM
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truck cutting out a little

I have a 2004 f-250, 4X4, auto transmission, 178500 miles on it, completely stock and has been its whole life, still has all the egr stuff. I don't know much about these trucks, i had a cummins and decided to switch over to the powerstroke, hope i made a good decision. i have read several threads about this, but i have a different issue than all the ones i have read about. my truck will start and run fine until i get to about 65 then it will cut out, but only enough where you can feel it, the RPM gauge does not even jump, and it puffs black smoke out of the exhaust, but if i floor it, it blows black smoke and runs like nothing is wrong, then i slow back to 65 and it runs fine for a while. i pulled the egr valve and cleaned it, it was not that dirty, but it came out easy and i think the o-rings were not sealing correctly. any suggestions? thanks for the advice in advance.
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Old 03-04-2013, 08:46 PM
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truck cutting out a little

I do recall when it was ever real "easy" to pull an EGR valve. Replace the O-rings as you should feel it kind of pop in when you install the valve. Also, I'd check your FICM volts when starting.


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Old 03-05-2013, 04:28 AM
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thanks for the fast reply. i will get the o-rings today and replace those, i am sure i can find instructions on testing the voltage, and i will try that today. also my truck has no check engine light, and no codes ( i checked with an OBDII reader). all gauges show everthing is fine.
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Old 03-05-2013, 05:50 AM
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truck cutting out a little

This link has near the end where you need to connect a multimeter. FICM Mod
If you find your voltage drops during cranking a few volts Bullet Proof Diesel makes THE best stuff around.


New FICM, now I have a few questions
LOL. In my previous post I meant "I don't recall...."


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Last edited by Term3; 03-05-2013 at 06:17 AM.
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Old 03-05-2013, 04:52 PM
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thanks for the useful information. i tried to get a gasket set for the egr valve, but every parts store in my area does not have any and they say they can't get them. i called the local ford dealer, they said the gasket set is $75. i think i will have to order it from rockauto or something. ill check the voltage on thursday when i have someone to turn the key on while i watch the volt meter. wish i could test it sooner. ill post my results asap.
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Old 03-05-2013, 06:12 PM
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truck cutting out a little

Any Viton O-ring the proper size and thickness will also work. Most machine shops will have a good selection of O-rings. Viton is usually a kind of brown to tan in color.


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Old 03-06-2013, 06:28 AM
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this is what i ordered.
More Information for STANDARD MOTOR PRODUCTS VG169

you are extremely helpful. i can't wait to fix this problem.
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Old 03-06-2013, 08:03 AM
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truck cutting out a little

No problem, that's the whole purpose of these forums.


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Old 03-07-2013, 05:33 PM
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i went to work on the truck today. i had the coolant reservoir pulled to the side and the little plate off the FCIM, there are 7 screws in it. after i got that far, i found out my volt meter was screwed up. so i went to town to buy another and got home too late to test it. ill test it tomorrow and post my findings. my egr valve gasket and o-ring set will be in tomorrow too.
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Old 03-08-2013, 06:24 PM
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well i got the gasket and o-ring set and put it in and that didn't fix the problem. the FICM volts were 49 with the key on and 48.5 with it started. hope those are good numbers. although after i put the o-rings on the egr valve the truck ran like it always does. it ran great and then when it decided to cut out, i floored it (cause that fixes it for a while) and it poured black smoke out of the tail pipe, which it used to puff black smoke not pour it out. any suggestions?
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