6.0L Surges at highway speed then died.... - Ford Powerstroke Diesel Forum
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post #1 of 14 Old 11-07-2019, 12:32 PM Thread Starter
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6.0L Surges at highway speed then died....

Hello Everyone,

2004 F-250 Extended Cab 6.0L Turbo Diesel

First time posting and first time diesel owner. I have done just about everything on a gas engine, but, never on a diesel.

Bought this truck with 230K on it. Seems to run great, lots of power. Anyway, I was driving stop and go about 15 miles and then hit the highway. About 20 miles on the highway, it seemed to studder and surge, never died and never really lost too much power. I was able to keep it around 60MPH. When I went to get off the exit and pay the toll, it died, I was able to pull over. I tried to restart and no go. Finally killed the batteries so I had it towed to a friends shop. They are heavy duty International and I did not realize they don't work on Fords. One of the mechanics took a look at it, charged up the batteries and it started right up. They took it around drove it a bit and it seems to run good. They did say the oil looked a little above full, which could indicate fuel leaking into oil via head gasket.

I did not press them too much since they did me a favor. This is my second vehicle so I am not pressed for time and figured I would try and troubleshoot myself.

Questions.

1)Any ideas what this could be?
2)Anyone ever had this issue and found it was the head gasket? I have done the head gasket on a 2004 Honda Accord (4 cylinder). Are head gaskets on the diesels similar in scope?

Thanks for any assistance.
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post #2 of 14 Old 11-07-2019, 01:37 PM
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fuel leaking into the oil would be an injector, not head gaskets. Get the codes read w/ a quality code reader.

Mark
06 F250CC SB FX4 Lariat; ARP studs; OEM gaskets; Banks exhaust; DynaTrac Ball joints; RACCCV6000; JimmiJammers; Ravelco; SynchroMax in trans case; Fumoto valves; Harpooned; Blue regulator spring; DashDAQ; PHP FICM; RiffRaff boots; DCPower 270AXP; Power Inverter; Bilstein shocks; BPD EGR cooler, radiator, water pump; SCT w/ SRL+; Rotella ELC Ultra Coolant; X2Power AGM batteries
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Last edited by bismic; 11-07-2019 at 06:25 PM.
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post #3 of 14 Old 11-07-2019, 01:51 PM Thread Starter
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sorry, may be a dumb question...I have a "ZURICH ZR8 OBD2 Code Reader With Live Data" code reader. Will this give me the information I need? I also have a USB scan tool that I have used with OBDwiz on my vehicles.

Thanks for the quick reply...

One other quick question - If it is injectors, are they complicated to replace? I have done that many times on gas vehicles.....
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post #4 of 14 Old 11-07-2019, 05:03 PM
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Stick with Forscan or Torque Pro for the codes

Yes injectors are similar, just held in with a clamping bolt -- but lets not go there yet

You said it ran after the batteries were charged -- does the alternator output the correct voltage?
what do the cables look like -- clean? -- also the other end of the cables where they connect to the frame and block

A lot(well all) of the engine depends on good power to the computers -- so need to be sure of this

In my defense, I was unsupervised
.
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post #5 of 14 Old 11-07-2019, 05:41 PM Thread Starter
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I will check voltage output and cleanliness of cables first thing tomorrow. Truck was running ok until it died, then I tried to start and batteries went dead. After sitting for a couple days it started right up after charging.
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post #6 of 14 Old 11-08-2019, 06:57 AM Thread Starter
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I checked and Alternator is putting out 14.6V. All connections looked clean and I went ahead and cleaned them up anyway.
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post #7 of 14 Old 11-08-2019, 08:55 AM
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Again - read the codes

Mark
06 F250CC SB FX4 Lariat; ARP studs; OEM gaskets; Banks exhaust; DynaTrac Ball joints; RACCCV6000; JimmiJammers; Ravelco; SynchroMax in trans case; Fumoto valves; Harpooned; Blue regulator spring; DashDAQ; PHP FICM; RiffRaff boots; DCPower 270AXP; Power Inverter; Bilstein shocks; BPD EGR cooler, radiator, water pump; SCT w/ SRL+; Rotella ELC Ultra Coolant; X2Power AGM batteries
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post #8 of 14 Old 11-08-2019, 09:08 AM Thread Starter
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I forgot to post that.
(WARN) [11:36:58.078] Checking FTDI #1:113010982303...
(OK) [11:37:04.899] Connection to adapter has been established: FTDI #1:113010982303
(OK) [11:37:04.901] Adapter: OBDLinkSXr4.2 STN1130 v4.0.1 (ELM327 v1.3a)
(OK) [11:37:05.233] Connection to vehicle has been established
(OK) [11:37:06.095] Vehicle: Ford F-Series Super Duty Direct Injection - Turbo 6.0L 2005 ( 2005 MY ), VIN: 1FT*********93217
(OK) [11:37:10.357] Found module: TCM - Transmission Control Module
(OK) [11:37:14.609] Found module: PCM - Powertrain Control Module
(OK) [11:37:25.207] Found module: OBDII - On Board Diagnostic II
(OK) [11:37:25.841] Found module: ABS - Antilock braking system
(WARN) [11:37:26.011] DTCs in ABS: U1900-30, B2900-20
(OK) [11:37:26.278] Found module: TBC - Trailer Brake Control Module
(WARN) [11:37:26.741] DTCs in TBC: B1318-20
(OK) [11:37:27.107] Found module: IC - Instrument Cluster
(WARN) [11:37:27.654] DTCs in IC: B1352-60, U1900-20, B1318-20, B1360-20
(OK) [11:37:29.704] Found module: RCM - Restraint Control Module
(WARN) [11:37:30.653] DTCs in RCM: B1318
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post #9 of 14 Old 11-13-2019, 01:57 PM Thread Starter
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I feel like the worlds dumbest person right now. I changed the oil and oil filter. I also changed the fuel filters. While I had it apart I figured I would change the fuel injector orings on the driver side. I did all that and went to start and I get crank no start. I did just notice that I did not connect one wire pigtail, I remember seeing it and then forgot to connect. I just spent the last hour trying to track down where it connects. I cannot believe how stupid I am. Everyone told me to check the codes....

So, below is a pic of the connector. It is attached to the (I think) mass air flow sensor connector, but, I cannot find anything to connect it.

Could this be the reason for no start? I did cycle the car key on for 30 seconds without cranking, key off, 6 times, which Diesel Tech Ron says to do after changing fuel filters. Right now batteries are charging and I am frustrated beyond words.

I had a truck that was running, and I tried to make it run better....what an IDIOT I am.....
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Last edited by pbennison; 11-13-2019 at 02:00 PM. Reason: Pictures
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post #10 of 14 Old 11-13-2019, 04:26 PM
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Pull the air filter back out and reassemble it correctly, looks like the "lid" is crooked

You put the filter all together -- then put the assembly in to place as one part -- it will fit

That harness is likely the Mass Flow Sensor(which I think only uses the temp sensor part)

Are the FICM plugs all seated into position -- easy to break off the retainers

And don't beat your self up -- we all been there at one time of another
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In my defense, I was unsupervised
.
2006 F250 Lariat FX4 cclb
Torque Pro and OBDLink MX bluetooth monitor
General note:
For all those wanting a premium silicone sealer Kubota 70000-73764 is the best your gonna find. This is a hybrid gray silicone that uses solvent rather than acid to start the curing reaction, this makes it safe for aluminum and and any surface that involves coolant.
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