Vandalized E350 - shredded paper in fuel tank?

[E350wcvan]

I'm a first time diesel owner and a wheelchair user, so I'm not really looking for do-it-yourself answers as much as I am in advice on how to respond to Ford dealer service.

About a month ago I bought an '03 E350 Super Duty 7.3 van, with only 8,600 miles, equipped with everything to make it wheelchair accessible. It ran fine for about a week, then began to sputter or stutter everytime we drove it a few miles.

The dealer has changed a fuel filter, a solenoid and valve, fuel pump (twice!), and the fuel water seperator. Nothing fixed the problem. So we had the tank dropped and cleaned where they found what seemed to be shredded up paper mixed in the fuel. It was a mess, but they cleaned and replaced the tank. We drove it about 90 miles afterwards and it started doing the same thing. Now they say an in-line filter may need to be changed a few times to get all the gunk out. Does that sound right to anyone? I keep wondering if it's an electrical problem, but the Ford dealer here claims to have a good diesel man on staff.

Right now I'm just puzzled and looking for advice. I rely on this transportation for my job and in fact I bought the van because of the solid reputation of the 7.3 powerstroke.

Thanks for all your advice and I apologize for the length of the post...

[bigwes]

id have them double check the tank again incase anything came back in, id also go ahead and replace all the line and filters...sorry bout your luck, i hate it when people lower themselves to messing with a vehical

[E350wcvan]

I've almost given up on the idea that the only problem I have was paper in the fuel tank.

It will run fine for a distance, 5, 10 miles, one time almost 100 miles. A garage said that I was getting an error code:

P1280 - ICP circuit out of range low

Everything I've read here and on the web says this is an electrical problem now. The sensor itself, loose wiring, or the CPM.

Any ideas? I've been 5 weeks without my transportation now and I'm getting desperate!

[mech2161]

What year is the van and had it sat for a long time? I wounder if what they actually cleaned out of the tank was algea. Diesel fuel can go bad in the right situation. There are additives you can put in the tank to take care of it. If it's too bad you'll need to start over and clean the entire system. Your dealer should be aware of this.

[mech2161]

Any updates on this?

[E350wcvan]

Still having problems. The second dealer (I gave up on the first) has it now and just yesterday the shop foreman was test-driving it and this he got stranded because it acted up. Earlier this week he said the tank had gunk in it and thought it was algae. So the tank was dropped again and re-cleaned, but it wasn't algae. It was still paper. So they missed some the first time it was cleaned. But now since it's been cleaned again and it's acted up on the foreman they say the fuel line and filter all appear clean. They've read a whole slew of codes but I don't know which ones. So I believe now that coincidentally, I've had more than one problem all along. I keep insisting they run down that P1280 code and check out the ICP sensor/wiring, but they haven't. Maybe now they will...

[mech2161]

There have been some cases where the harness over the DS valve cover has rubbed through.

[E350wcvan]

If I could get the dealer to check out some of the sensors and common electrical problems I think they'd find the problem. For some reason they keep resisting that suggestion. So yesterday we had a heart-to-heart discussion about it this since it's now been 2 months with little progress. I hope to hear from them yet today...

[EdNewman]

The problem is not paper, it is the spray on lining to the fuel tank. There is a problem with it and it breaks down over time and flakes off. We have about 50 Ford trucks from 99-07's and both of our 2003 E350's and our 2003 F350 have had this problem. It requries a new tank, fuel pump and filer and lines and if you don't catch it early enough you can clog the entire fuel systems. We are currently fighting with Ford over compensation on these. Anyone who has a 2003 should have their tank dropped and inspected before it becomes a big problem. Go back and fight the dealer and Ford on this one!

[E350wcvan]

I'd agree with you, but the tank in this particular van isn't a stock tank. The original was removed when the interior floor was lowered about 4 inches from the back bench seat to the front seats which creates head room for a wheelchair user. A different tank was installed behind the rear axle.

The problem has been fixed though, but since I heard the solution second hand from my wife, I'm not 100% clear what they did yet. She thinks they changed the Exhaust Back Pressure sensor, but I'm not sure she remembers correctly.

I'll post again when I find out what it was for sure. I'm waiting for a call from the dealer...