intermittent surge/stumble, died driving - no pedal response - Ford Powerstroke Diesel Forum
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Old 10-10-2011, 06:55 AM
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intermittent surge/stumble, died driving - no pedal response

2002 F350 7.3L
6spd
117K
TS 6 pos programmer/chip
BHAF
4" Exhaust

I have had an intermittent surge/stumble for the last 3 years. Maybe once every few weeks would get a surge or stumble. Was much worse with the 10K resistor. Finally a couple weeks ago I threw out the resistor and have been running stock with less pronounced surge/stumble but still does it every few weeks.

Yesterday I installed the TS 6 pos programmer and took it for a test drive. Ran great, no issues. Later in the evening I was meeting a guy to trade some parts.

Took off and about 3 miles from the house, the truck stumbled and the throttle pedal was unresponsive. Check engine line, water in fuel, and wait to start lights all came on. The tach also dropped to zero, even though the motor was still turning. The truck was still running, but the pushing the pedal made no difference. I let it coast to a stop and it eventually died.

Checked the PCM/programmer connection, PCM/wiring harness connection and Valve Cover Harness connections and all seemed ok. I unplugged the ICP and it started right back up.

Thinking I had pinpointed the problem I took off again. Made it about 10 more miles and the truck died again, same symptoms. I was half way there at this point, so I let it sit a few minutes, then started it up and headed on.

For the next 10 miles it died probably 5 or 6 times. The guy had driven 2 hours to meet me, so I wasn't going to leave him hanging.

I finally made it to the rendezvous point and swapped parts. Checked everything on the truck one more time (I left the house with my toolset sitting on the workbench). Started the truck and drove 25 miles home without a hiccup.

The issue was there before the TS programmer, but was never more than a hiccup. The issue happened both on the 100hp program, 75hp program and stock. I will be pulling the programmer and test driving to rule out a bad programmer, or loose connection issue with it. Contacts for the programmer were cleaned and making good connection.

It did rain yesterday and I have read on here that sometimes brings out TPS issues. That was the first real rain we have had for a year, so troubleshooting that one might take some patience.

At this point I am leaning towards a bad throttle pedal position sensor or ICP. The ICP does not have any visible oil in the plug.

Am I headed in the right area? Missing anything obvious?

Anyone around Austin/Dripping Springs with a code reader want to help me out and make some $$ as well?

Thanks,
Brent
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Old 10-10-2011, 07:25 AM
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Yea, I too would throw a TPS in it, they have a history of issues and why not eliminate it, if not for the future alone
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Old 10-10-2011, 07:29 AM
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yeah I figured I would do that, if nothing else hopefully get rid of the surging. That may be the whole issue, but my gut says probably not.

Also CPS was changed about 5000 miles ago. I know it could still be bad, but changing it had no effect on the surge/stumble issue.
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Old 10-10-2011, 08:06 AM
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Just remember one other symptom. When I had the 10k resistor in, occasionally on startup the CEL would be on and stay on for 30 seconds or so. While the CEL was on, the truck felt stock. I would be driving down the dirt driveway in 1st gear, medium throttle and the CEL would shut off, the the idle/motor would jump and the truck would spin the tires. It was like the resistor wasn't working for 30 seconds, then would "wake up".

This seemed to happen for about a week or 2, then disappeared for a few weeks, then was back for a week, and hasn't happened since.

I can't totally remember, but it seems like it only happened on days over 90 degrees, but not every day over 90.
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Old 10-19-2011, 12:50 PM
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some of your symptoms i recognize from my truck my Cam position sensor went bad i took it to the dealer cause they had a recall on it and that cleared it right up so just check your recalls.
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Old 10-19-2011, 05:36 PM
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Mine has been in for the CPS recall and it didn't change it at all.
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