Chugging/loss of power and a touch of advice - Ford Powerstroke Diesel Forum

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post #1 of 26 Old 05-24-2012, 10:56 AM Thread Starter
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Chugging/loss of power and a touch of advice

Went to tow the GF's horse trailer after letting my '96 sit for a while and noticed it would intermittently loose power, chugged under load and the cruse control wouldn't work with no CEL given. Poked around and found both pigtails on the drivers side valve cover harness had burnt pins.
Needing the truck, I picked up a new gasket/harness/pigtail kit from the local Napa store and threw it in. Easy enough, or so I thought...
Took 'er for a test drive an she ran worse than before. MAJOR loss of power and chugged even worse.
Pulled her back into the garage and started poking around with the OHM meter and found the rear harness plug was only giving ~.1 from INJ+ to INJ-. Pulled the cover and swapped harnesses (front to rear) to ensure it was the harness's fault. Sure enough, was (whew). Have a replacement waiting at NAPA now, so thats where we sit.

Long story short, DONT BUY CHEEP CHINA junk!!! even if the nearest ford stealership is 60mi away...

It is amazing, by the way, that a 7.3 will run on just 4 cylinders...

'96 ext cab 4x4
ZF5
DIY intake
3" dp
DIY 4" exhaust
Gauges
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post #2 of 26 Old 05-29-2012, 01:40 PM
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Yeah these trucks certainly like their USA parts
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post #3 of 26 Old 05-30-2012, 02:29 PM
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Originally Posted by White95f250 View Post
Yeah these trucks certainly like their USA parts
Assembled in mexico........

Sent from my SCH-I500

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

SEE MY OIL COOLER REPLACEMENT AND EGR DELETE - http://www.powerstroke.org/forum/gen...tml?highlight=
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post #4 of 26 Old 05-30-2012, 09:27 PM
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North American*
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post #5 of 26 Old 05-31-2012, 04:51 AM Thread Starter
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Yeah, coulda sworn some of these are/were put together in Canada though.
Well, she's runnin ok now. Hoping these don't burn out too soon. Should still run through all the injector tests and what not, am a touch skeptical that she has the power she should

'96 ext cab 4x4
ZF5
DIY intake
3" dp
DIY 4" exhaust
Gauges
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post #6 of 26 Old 06-03-2012, 08:03 AM
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Sorry to hijack, but I've got one that has started melting and giving me issues, if Im gonna replace one should I just go ahead and replace both? Or is it overkill?

Early 99, 6 speed, ccsb, leveling kit on 35's, 6634, straight pipe, diablo chip.
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post #7 of 26 Old 06-04-2012, 04:49 AM Thread Starter
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Up to you. Me, just replaced the one side. Might as well get as many miles outta the other as possible, unless you're always way out in the boondocks I suppose

Edit: OHM it out, if she's reading weird throw a new one in...

'96 ext cab 4x4
ZF5
DIY intake
3" dp
DIY 4" exhaust
Gauges
TW

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post #8 of 26 Old 06-04-2012, 02:27 PM
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Yeah I went ahead and ordered both, since I routinely make long drives in my truck. Thanks for the advice though

Early 99, 6 speed, ccsb, leveling kit on 35's, 6634, straight pipe, diablo chip.
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post #9 of 26 Old 06-04-2012, 06:37 PM
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Hey guys, I pulled the valve covers tonight and theres nothing at all wrong with the passanger side inside or out other than oil is inside the plugs, and the plugs under the drivers side look good, only place with the burnt pin is the one in the front outer plug on the drivers side. but oil is getting through the plugs on this side too, help me out, are these my issue? And my injectors have different numbers on them, 6 of them are AA1816187C3 and 2 are AA1821836C2. what does this mean.lol.

Early 99, 6 speed, ccsb, leveling kit on 35's, 6634, straight pipe, diablo chip.
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post #10 of 26 Old 06-05-2012, 04:54 AM Thread Starter
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As far as the injectors go (some one can correct me if I'm wrong) as long as they are AA you should be good, but you might research that to make sure.

one burnt pin can kill the 2 cyl that it's hooked to, or at least make those two run erratically. You could just replace that one harness an pig tail, but with oil in the other, replace the whole setup. Others on this site quote oil in the plugs as being a bad sign, personally dont have any experience to say yea or nay. Can't see it being good at all though (the whole leaking thing)...

'96 ext cab 4x4
ZF5
DIY intake
3" dp
DIY 4" exhaust
Gauges
TW

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