Help! 97' Problems! Shop replaced ALL injectors, still quitting! - Ford Powerstroke Diesel Forum
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Old 12-27-2010, 09:51 PM
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Help! 97' Problems! Shop replaced ALL injectors, still quitting!

Hi Everyone, thanks for your patience, I'm new to the forum (this is a bit long). I drive my beloved "Bertha" a 97' 7.3 3/4 ton that I've meticulously maintained. Only 5K a year on her since I've bought her 8 years ago with 110K. I now have 150K on her. Have replaced transmission, transmission coolant system, 2 fuel pumps, water pump, etc.. change oil every 3K. Only use to pull my 2 horse trailer.

One night truck starts running really rough as we are coming up a hill. Happened after I switched fuel tanks. Loses power, stalls out, starts, but just chugs (barely). I get to side of road. Stranded with 2 horses at night.

I tow truck into independent diesel shop. They replace rear exhaust sensor and give me back truck. Truck dies 10 miles from shop. Won't start, really rough when it does start, then only for a minute. Towed back to shop. Next day I was informed I needed 4 new injectors. Guaranteed that the shop had eliminated all other possiblities. I replace ALL injectors with NEW Ford parts (7 hours labor plus $354 per injector). Shop also states that front fuel tank has some contaminant (gas/acetone?) in it. They drain tank and fill with diesel. I have NEVER put anything but diesel in my truck...Truck returned to me. Dies 4 miles from shop, exhibiting exact same original symptoms (though new injectors were installed). Towed back to shop. Shop then states that the software uploads that guide the injectors (?) didn't take. They redo upload and give me back my truck. Yes boys and girls, the truck then dies 1/2 mile from the shop, shuddering, running super rough. I manage to get the truck back to the shop but it's the Friday before Xmas and they are closed. After talking in depth to a diesel specialist at the Bureau of Automotive Repair, I have truck towed to local dealer for additional diagnosis.

Sorry this is so long! Any ideas? Am I right to be concerned that I just paid $4K for injectors I may not have needed? Could something else be causing injectors to fail, as opposed to four injectors failing at once? The truck has broken down twice since the new injectors were installed.

Also,an aside question. Shop wouldn't provide injectors for inspection since they were returned for "core charges". I understand core charges in general but with new factory injectors, should there still be core charges? Thanks in advance for any help you can give me!!! Jennifer
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Old 12-27-2010, 09:57 PM
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First off welcome to the Org!

Sounds like a PCM to me, my truck did the same stuff.

The core charge thing is normal. But to be honest you probably didnt need the injectors.
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Old 12-27-2010, 10:01 PM
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PCM? Is that a prep school or a breath mint? Help me out here as I'm a cowgirl not a mechanic Any details would be appreciated as I am really interested in learning about my truck.
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Old 12-27-2010, 10:04 PM
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haha alright PCM (powertrain control module) also called ECM (engine control module) or in simple terms its the computer. Can be found on the drivers side of the firewall it has a huge plug with a bolt in the middle of it. easiest found by looking over the drivers side fender and looking down. its the plug on the firewal

where abouts are you located? Someone local to you might be able to swap one real quick to check it
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Old 12-27-2010, 10:10 PM
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I'm in Santa Cruz, CA. I don't mind paying the dealer to diagnose, especially if it will support the possibility of me challenging the new injector charges. And thanks for your speedy response! I really appreciate it.
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Old 12-27-2010, 10:12 PM
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No problem. Well sadly depending on the dealer anymore they dont know crap about a 7.3. But a good ford dealer with a healthy service department aught to do alright.
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Old 12-27-2010, 10:18 PM
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Ha ha, yes, but my Ford dealer has a pretty chill owner. It was he who suggested I call BAR and file a complaint. The Ford service dept does lots of old trucks since we are all broke and out of work here in California

Anyway, I'll let you know what happens and thanks for the PCM tip, I'll talk to the mechanics at the dealership and hope they aren't wet behind the ears (like me).

Wish we had a reliable independent shop but can't seem to find a recommendation close by. Thanks again for your help. Sorry about your weather ;
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Old 12-27-2010, 10:20 PM
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haha yeah a good diesel mechanic is rare these days. But when you find one you are good to go

my weather?
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Old 12-27-2010, 10:22 PM
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Isn't it blizzarding on the east coast? My sister is snowed in in MA.
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Old 12-27-2010, 10:24 PM
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I keep hearing that but my yard is dry and sky is clear here in central PA lol
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