Help! Not sure what to do anymore to fix this thing... - Ford Powerstroke Diesel Forum
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post #1 of 20 Old 08-09-2012, 12:28 PM Thread Starter
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Help! Not sure what to do anymore to fix this thing...

I've got an '05 excursion 6.0, 103k on it and it's becoming a major headache. I'm stumped.

Here's the rundown:
When we bought it, it ran fine for a few days then stalled & died as we were braking & turning; towed home.
* replaced alternator (CS screen reading low battery)
* stalled again on next test drive, tow home.
* replaced BPS
* torque converter clutch reading was really weird (MAC scanner)
* took to local shop & they tested & replaced ICP, IPR, resealed branch tubes, replaced 2 injectors that were leaking.
* stalled again (low oil pressure) & had it brought home (CS screen had kicked the bucket by this time).
* replaced STC - got tested at local shop & tested good!
* wife drove it out and it started the stuttering all over again, surging & losing power etc @ 65 mph. She limped it home.
* I drove it again and thought it felt like it was surging in all gears, stuttering etc. It stalled & we boosted it for about 15 mins, and it struggled to life. Made it home
* BOUGHT AE!!
* Found a bunch of electrical codes and got to work on them - most of them are gone now except for P0500 & U2016, also the 2WD solenoid (can't remember the ###).
* took it for another test drive while monitoring it and it stalled again, along with the surging & lurching. Here's some readings that came up:
engine oil temp - 191
coolant temp - 193
FICM stayed steady.
*tried to restart & had an ICP reading 350-380 psi and it wouldn't start.
* wife came out to boost it and we let it sit for about 15 mins (temp was 185 by then) and it struggled to life again. Just before it started AE had an ICP reading of over 4000 psi, no cranking, nothing.

according to AE my vehicle speed was 0.2 mph and my speedometer was reading 50mph.
* at idle TC slippage was Desired=1020rpm, Actual=20rpm

Could a bad PCM harness cause all this mess???

Any other ideas? Not sure where to go with this anymore...

2005 Excursion Eddie Bauer 6.0
104xxx miles
Sinister Basic Solution kit
Powerstroke Powermax Turbo
Air Dog Fuel Air Separation System 100GPH
ARP Head Studs
Edge CS Insight & SCT Combo

Last edited by 2005Excursion6.0; 08-09-2012 at 01:31 PM.
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post #2 of 20 Old 08-10-2012, 05:46 AM Thread Starter
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no one has any ideas???? I'm hoping some of these problems might be related to a particular harness....but I'm not super familiar with these trucks (yet)...

any input is appreciated!

2005 Excursion Eddie Bauer 6.0
104xxx miles
Sinister Basic Solution kit
Powerstroke Powermax Turbo
Air Dog Fuel Air Separation System 100GPH
ARP Head Studs
Edge CS Insight & SCT Combo
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post #3 of 20 Old 08-10-2012, 06:09 AM
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Have you had your batteries load tested. Continual operation on low voltage can cause FICM and PCM damage and some really strange results.

What you are describeing makes me believe a failing PCM due to low voltages/amps.
There may be physical damages or just data corruption, you need to have it checked by Ford and maybe even reflashed. Your FICM may be damaged as well.


Lord I shall lead them to the water but I will not try to make them drink
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post #4 of 20 Old 08-10-2012, 06:55 AM Thread Starter
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Quote:
Originally Posted by dannyboy950 View Post
Have you had your batteries load tested. Continual operation on low voltage can cause FICM and PCM damage and some really strange results.

What you are describeing makes me believe a failing PCM due to low voltages/amps.
There may be physical damages or just data corruption, you need to have it checked by Ford and maybe even reflashed. Your FICM may be damaged as well.

I have had the batteries tested and they tested good.

What does a reflash cost on average??

2005 Excursion Eddie Bauer 6.0
104xxx miles
Sinister Basic Solution kit
Powerstroke Powermax Turbo
Air Dog Fuel Air Separation System 100GPH
ARP Head Studs
Edge CS Insight & SCT Combo
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post #5 of 20 Old 08-10-2012, 07:18 AM
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Around here avg. is a $100.00 depends on your area. A few phonecalls will let you know at your area.

A reflash will only do any good if it is data corruption it won't fix a physical issue. It also will not always cure a data issue sometimes they will have to be sent to the factory for complete reprogamming.


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Last edited by dannyboy950; 08-10-2012 at 07:22 AM.
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post #6 of 20 Old 08-10-2012, 09:59 AM Thread Starter
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Quote:
Originally Posted by dannyboy950 View Post
Around here avg. is a $100.00 depends on your area. A few phonecalls will let you know at your area.

A reflash will only do any good if it is data corruption it won't fix a physical issue. It also will not always cure a data issue sometimes they will have to be sent to the factory for complete reprogamming.
Ok, thanks for the help so far. Appreciate it!

2005 Excursion Eddie Bauer 6.0
104xxx miles
Sinister Basic Solution kit
Powerstroke Powermax Turbo
Air Dog Fuel Air Separation System 100GPH
ARP Head Studs
Edge CS Insight & SCT Combo
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post #7 of 20 Old 08-10-2012, 11:37 AM
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Quote:
Originally Posted by 2005Excursion6.0 View Post
I've got an '05 excursion 6.0, 103k on it and it's becoming a major headache. I'm stumped.

Here's the rundown:
When we bought it, it ran fine for a few days then stalled & died as we were braking & turning; towed home.
* replaced alternator (CS screen reading low battery)
* stalled again on next test drive, tow home.
* replaced BPS
* torque converter clutch reading was really weird (MAC scanner)
* took to local shop & they tested & replaced ICP, IPR, resealed branch tubes, replaced 2 injectors that were leaking.
* stalled again (low oil pressure) & had it brought home (CS screen had kicked the bucket by this time).
* replaced STC - got tested at local shop & tested good!
* wife drove it out and it started the stuttering all over again, surging & losing power etc @ 65 mph. She limped it home.
* I drove it again and thought it felt like it was surging in all gears, stuttering etc. It stalled & we boosted it for about 15 mins, and it struggled to life. Made it home
* BOUGHT AE!!
* Found a bunch of electrical codes and got to work on them - most of them are gone now except for P0500 & U2016, also the 2WD solenoid (can't remember the ###).
* took it for another test drive while monitoring it and it stalled again, along with the surging & lurching. Here's some readings that came up:
engine oil temp - 191
coolant temp - 193
FICM stayed steady.
*tried to restart & had an ICP reading 350-380 psi and it wouldn't start.
* wife came out to boost it and we let it sit for about 15 mins (temp was 185 by then) and it struggled to life again. Just before it started AE had an ICP reading of over 4000 psi, no cranking, nothing.

according to AE my vehicle speed was 0.2 mph and my speedometer was reading 50mph.
* at idle TC slippage was Desired=1020rpm, Actual=20rpm

Could a bad PCM harness cause all this mess???

Any other ideas? Not sure where to go with this anymore...
First one noted in red. If your only able to build 300-400 psi of HPO then the truck will not start it needs to see at a minimum of 500 psi before the ficm will fire the injectors.

Second note in green that sounds like AE was reading ICP DESIRED pressure as it wants to see high pressure in the system in order to fire while the engine is going to be cranking over.

I too believe you are experiencing a failing/failed FICM/PCM you need to take it to ford and have them diagnose the problems your having. There is only so much one can do at home to diagnose these problems. Sometimes the dealer is the only ones with the diagnostic equipment to be able to tell exactly what is going on with the vehicle.

If you just bought the truck and started having problems with it a few days after why didn't you take it back to where you bought it from and demand either your money back or that they fix it or reimburse you for all repairs you have made to the vehicle?

l BRYAN l


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post #8 of 20 Old 08-12-2012, 09:04 PM
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Check all the connections under the FICM, have seen bad connections there cause some weird crap.
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post #9 of 20 Old 08-14-2012, 01:55 PM Thread Starter
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Quote:
Originally Posted by altadiesel View Post
Check all the connections under the FICM, have seen bad connections there cause some weird crap.
Yeah, it's all good under there. We're going to replace the HPOP & the other 6 injectors that haven't been done yet and see where that leaves us.

2005 Excursion Eddie Bauer 6.0
104xxx miles
Sinister Basic Solution kit
Powerstroke Powermax Turbo
Air Dog Fuel Air Separation System 100GPH
ARP Head Studs
Edge CS Insight & SCT Combo
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post #10 of 20 Old 08-14-2012, 04:13 PM
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Quote:
Originally Posted by 2005Excursion6.0 View Post
Yeah, it's all good under there. We're going to replace the HPOP & the other 6 injectors that haven't been done yet and see where that leaves us.
Subscribed! I gotta see this, changing hpop and injectors will not fix all the described electrical mayhem.

Sent from my phone that somebody didn't help me get.

Unfortunately had to Sell my ......2004 KR CC SWB FX4 - Edge insight cts, blue spring upgrade, updated HFCM drain plug, XDP coolant filter, CAT EC-1 rated coolant, Custom Diesel EGR delete, CAT delete, Rotella T6

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