Intermittent Power loss, surging idle, rough idle? - Ford Powerstroke Diesel Forum
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Old 10-07-2009, 10:39 AM
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Intermittent Power loss, surging idle, rough idle?

Ive got a 2004 f350 6.0 and it has a extremely weird condition. Ive noticed that its gotten worse with colder weather. Truck always starts up, never dies. It does have a rougher start up at cold start now. At times the truck runs excellent, lots of power and runs like a champ. Intermittently it will act up. Symptoms are engine missing at idle, truck surges at idle and sometimes has no power when you try to push on the accelerator. In a matter of minutes that all changes and works perfect again. Its very sporadic. Comes and goes when it pleases. When its running at full potential it shows no symptoms at all. This has been happening for the past 2 weeks but when it does act up the phases are starting to last longer. Ive changed the icp. It was not leaking or dirty but tried it anyways. Did not change it. I cleaned my egr at the same time and noticed that it ran MINT for 1 day with no issues and started to act up again the next day. Im in the the midst of cleaning it again as we speak because i didnt give it a perfect clean. Any ideas? Ive searched everything on the boards and seems like it can be a million things but everyone elses problems have led to no starts, continuous lack of power, leaks, etc. I find it odd that it runs excellent at one point in time and crappy the next. Its never popped up any dtc's either. Id take to the dealership but they are so hit and miss. They never seem to pin point a issue. I always end up diagnosing it myself. Any help would be greatly appreciated.
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Old 10-07-2009, 10:44 AM
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Also like to mention that i rebuilt the truck. Bought it with front end collision damage, frame needed to be straighten, dunno if they affected anything.
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Old 10-07-2009, 02:59 PM
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Update: Cleaned up the egr again, didnt do a thing. Its running terrible now. Barely moves with the pedal floored. Sounds like its running on 7 cylinders. Blowing no smoke, no codes
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Old 10-09-2009, 12:12 PM
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Let the truck sit over night. Started it today and started decent, not so much of a rough start. Let it warm up for 20 minutes and its running mint again. Went for a couple high power runs and no issues. I notice now if i rev it up at idle till about 3000rpm it blows blue\black smoke. Only smokes after about 2700 rpm.
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Old 03-28-2010, 01:24 PM
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did you figure it out? my 03 is doing the same thing.
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Old 04-21-2010, 11:11 AM
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FICM low voltage
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Old 04-22-2010, 04:59 AM
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Sounds just like the early symptoms of my 2004 F350 6.0L. It finally lead to a no start. I suspected the FICM was flaky. After trouble shooting it myself for a while, I finally got a mechanic at the dealership to check it out with their scanner. It was a bad FICM. My truck has 101K miles. The mechanic said the smoke was due to the injectors firing during the exhaust stroke. The Ford dealership here quoted me $700 for the FICM, $300 to install it, and $100 for the latest Flash, plus sales tax. However, I have seen remanufactured FICM's on the internet for $375. I plan to install it myself to save the $$$. Then, I'll take it to have it flashed. By the way, if it is the FICM, I was told these have a 100K mile (or 5 year) powertrain warranty with a $100 deductible. I'm checking into that now. If it an '06 or newer, I was told the warranty is 100k mile (or 8 year) powertrain warranty with a $100 deductible.

Last edited by DirtyEC; 04-23-2010 at 11:09 AM.
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Old 04-22-2010, 03:27 PM
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mine is doing the same thing going on 3 mo. it is not smoking however. and it might be doing it less with more fuel in the tank-i am still checking on that one.

it is driving me crazy. i'd hate to take it to the dealership.
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Old 04-25-2010, 06:40 AM
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mine too doing this, driving me crazy, any updates? camping season coming!
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Old 04-26-2010, 03:25 AM
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Mine does it too (2004 6.0 with 90K miles, Bully Dog PMT). It spits and sputters, bucks and surges intermittently but only when it doesnt have good temperature in it. It makes boost but has no power. When it gets to 150-160 degrees (coolant temp) it all starts to smooth out. To minimize the problem I have been doing a remote start when I get up in the morning and let it idle for 30 minutes or so. When it does act up, it seems like its not getting fuel or not hitting on all cylinders.
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