2004 6.0 problems - Ford Powerstroke Diesel Forum
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Old 08-12-2013, 10:23 AM
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2004 6.0 problems

Hi,
Joined this forum in hopes someone out there can help me solve the problem or at least explain it to me. I have a 2004 F450 w/ a 6.0 in it. I know, already have replaced the turbo 4 times in a little over 100K miles. Replaced the turbo about 3 -4k miles ago & ran like a new truck. Last week it started to stubble every once in a while. Sent it to local shop & it showed a cam sensor code. Had the guy replace the sensor, twice, 1 from a local auto parts & 1 from Ford.
After that, the truck would not start at all. The local shop got frustrated & not having the technology the dealer had, we sent it to the dealer. Dealer replaced computer, ficm, etc........ & couldn't get it to start. Now dealer is telling me the motor is gone & it's $16,000 for new one. Here's where I am confused. How can a truck which was running fine, other than a stubble here & there, all of sudden need a new motor. From cam sensor to blown up. I don't understand. Help.
Thanks for your thoughts, Sam
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Old 08-12-2013, 11:14 AM
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What's in your oil? If there's no metal in the oil, and no coolant in the oil I'd question their theory of a bad motor.
Maybe they missed a harness? A lot of cars won't start without the cam sensor harnesses plugged in..
.. Maybe there's a problem with the timing chain??
What kind of "not starting" is it? Just click click clicks or tries to start and doesn't? Any backfires? I don't know anything about Diesels, so I doubt anything I can say is too helpful, but I can only assume some kind of a leak down test would indicate if there's a real problem. Maybe rings are damaged??
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Old 08-12-2013, 05:06 PM
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Find a powerstroke specialty shop or diesel performance shop or someone on here that is close by with an autoenginuity.

A shorted out exhaust back pressure sensor will cause a no start as well as the fan clutch on earlier models. Just unplug and give it a go. I hate it when dealers give up and want to put in a new engine without discovering why it quit running.
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Old 08-12-2013, 05:20 PM
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I know you might think this sounds crazy but I don't think your cam sensor was the problem. My "war wagon" did the same thing and it was the FICM. I went to FICMrepair.com and got one with a 2 or 3 year warranty. Put it in and no start. Never had any starting problems before that (no long starts or hot or cold no starts). Turned the key and wouldn't even turn over and thought maybe it was a wiring issue. Turned out starter went bad. Dropped a new starter in (after the new FICM to fix the stubble) and bam she fired right up. I even tested my starter and took it to advanced to have it bench tested and they said it was okay. A buddy of mine works on 6.0's for the county and said it's your starter. Even though it's testing fine it's your starter. It was a lifetime warranty one from Advanced and he said make them give you a new starter. After a little haggling they handed over a replacement starter, got it on and she fired right up. Crazy like I said. I would start testing the easy free stuff before I go throwing money at it. Maybe somebody with more experience will chime in!
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Old 08-13-2013, 05:59 AM
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Bringing it back to the shop today & start looking at the simple things. Every truck & piece of equipment we own is a diesel. I have 3 Cummins, a Detroit, & 3 Cats plus my 7.3. I have never had a problem like this 6.0 is giving me. I'd have to bet money it's something simple. I know the 6.0 has been a problem for Ford
but it is still a diesel. The just to go without some kind of warning signs. I am a maintenance fanatic, old changes every 3K, etc. I take care of my trucks that's why this problem makes no sense. Thanks for your comments.
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