02 7.3 Excursion Randomly Stalls - Ford Powerstroke Diesel Forum
 
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post #1 of 8 Old 09-06-2019, 08:54 PM Thread Starter
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02 7.3 Excursion Randomly Stalls

Greetings all. I've searched, I've read, I have theories but I'm here to benefit from the collective theory of this forum and the interwebz.

I have a 2002 Excursion 7/3 4x4. I bought it with about 230K mile from an original owner with all records, bone stock and unmolested. I proceeded to put on a lift from CT Performance, zero'd all fluids and filters, new fuel pump/tank cleaned/screens replaced, new starter, batteries are less than 18 month old, etc ad nauseum - suffice to say before purchase I had an out of state Ford dealer do a PPI, then I had my local shop do a PPI, and I fixed everything they both found. My plan/theory/goal was/is to keep this vehicle at least 10 years if not forever. It is my wife's daily driver and I use it when towing our boat or going to our hunting camp.

No tuner, no performance upgrades.

Last week for the first time the vehicle died at speed while my wife was in traffic; a cop pushed her into a gas station. Would crank but not start.

I knew the camshaft position sensor was the most likely suspect - she happened to break down near an Autozone. I was able to install a sensor prior to AAA arriving - truck starts, I am all that is man. I noticed a power steering related hose leaking while I was down there and since the power steering pump and steering box had both been replaced in the past 12 months and I was due for an oil change anyway, it went into my friendly local independent diesel specialist.

Picked it up, drove fine for a few miles in the course of returning a rental and going home.

Next day my wife wanted me to drive it until we knew it was GTG. I dropped off my son at school, headed to the office and it died on me at 50 MPH.

Towed to friendly local independent diesel specialist - they couldn't find any codes, vehicle started right up. Their only theory was that it could be the Autozone sensor. I replaced it with a Motorcraft CPS sensor for peace of mind, drove two miles to Autozone to return their POMS sensor, and when I went back out in the parking lot...

Cracked, wouldn't start.

My son and I walked to a restaurant, had dinner, came back, fired up and drove home.


SO - if that was all TLDR -

Vehicle stalls at speed and won't start until it cools down an hour or so
CPS replaced 2X, now has Motorcraft OEM CPS
No codes being thrown
Played with the pigtail connection a bit, doesn't appear to be the problem

So I know the ICP, IPR, PCM, ECU, wiring harness are the primary suspects

I have searched the forums and I've seen a variety of SIMILAR failure but no smoking gun, and it seems most of those stalls involved vehicles that would start after the stall without having to cool down.

Any brilliant insights as to are appreciated!!! I can't have my wife's DD with three kids stalling randomly and stranding them.

Side note - for those of you unfamiliar with Ron Burgandy - today my Excursion earned the unfortunate nickname Sex Panther - because 60% of the time, it works every time... I'm too much of a noob here to post a youtube link, but google will explain my user name to be a lot less aggressive - if not outright unfortunate - than it might appear at first blush.

Last edited by SexPanther; 09-06-2019 at 09:13 PM. Reason: clarifying no tuner
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post #2 of 8 Old 09-07-2019, 06:23 AM
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So first,,,, Yea - I got the "Anchorman" reference right away

But next;
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If you're gonna keep & maintain the truck yourself I strongly suggest you get access to the special scanner software you need to do it.

Here you have a couple of the most common choices;

1) If you want to do Everything you'll ever need to, then look at the AutoEnginuity + the Ford Enhanced Package (@ $350 - you add an old computer of some sort to run it with)

2) To retrieve most of the codes you'll need to help and even do some testing look at the FORscan Lite or TorqueApp (you add an Android device and Blue Tooth Adapter for @ $30) OR the Windoze version with a USB adapter. I like this one for BT Android -> http://www.amazon.com/BAFX-Products-...dp/B005NLQAHS/

Just a few years ago you needed to buy a professional scan tool because our trucks need to have a scanner with a Library containing both the Ford Proprietary AND the Diesel Specific codes in it. Add to that, our trucks are Not, specifically, OBD-II so the Generic scanners the Auto Parts Stores have are of little use to us. But today there are some very good App based tools, that are close to what the pro tools do, for fraction of the cost.


https://www.powerstroke.org/forum/99...sis-cheap.html

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This would have allowed you immediately determine if you have RPM (CPS) signal when it wouldn't restart. Similarly, it will give you insight into what the Hi-Pres Oil sensors are reporting when it won't start now. Big Help when you're stuck!

You're right, CPS is the most likely suspect, next I would say would be the IPR maybe. You have to think of what happens when the engine get's hot, what changes...

The Oil gets thinner, maybe foams if it's "gone bad". Thinner oil leaks past, marginal, O-Rings that thicker oil still seals "enough" with. Metal swells, things like the IPR pintle might get stuck in a too tight bore that's got crud in it. Electronics, like the CPS, get effected by heat as coils & clearances change.

It all can seem intermittent, but it's not really if cooling-off is the cure. Again, the best way to direct you would be to have that insight that even a $30 App & Adapter can give you (otherwise, you're just guessin' with your wallet....)
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post #3 of 8 Old 09-07-2019, 07:41 AM Thread Starter
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It pains me to say this, but I'm strongly considering doing the IPR, ICP, HPOP and anything else that can make this happen as preventative maintenance. This is my wife and kids daily driver. I bought it because it was supposed to be the million mile most reliable thing ever...

FWIW, oil has been fresh/changed since I first bought it and I believe the prior owner was good about that as well.

I understand it is 17 years old and has 240K - I'd rather spend a little up front to make sure she isn't stranded. I'm fortunate enough to have a job where doing the HPOP/IPR/ICP in advance along with other things that are likely to fail in this age/mileage range won't stop the baby from getting new shoes, but I'm not a rocket surgeon or anything like that where the answer is a frame up restoration...

I will invest in diagnostics for sure.

Any other suspects would be greatly appreciated!
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post #4 of 8 Old 09-07-2019, 10:37 AM
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Forget the HPOP, it would be much more likely that if this were a HiPres Oil issue you're problem would be injector O-rings or a stuck IPR (but again, knowing the ICP pressure would help to determine if it were HiPres Oil related).

As for an ICP issue, less likely, but simply unplugging it when it doesn't start, and having it fix the issue, is an easy no cost test (and that in itself might also be more of an indication of a pressure problem rather than just a Bad sensor too).

Get the tools you need to know what's preventing it from a Hot Restart
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post #5 of 8 Old 09-07-2019, 05:09 PM Thread Starter
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Diagnostic capability ordered - thanks for the link!

HPOP swap thought was more the replacement ahead of the inevitability of failure - as well as the replacement of the ICP - I want to eliminate the known issues that would be likely to create a situation like the one we're in now.
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post #6 of 8 Old 09-16-2019, 09:11 PM Thread Starter
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Update - so a great guy and good friend, we'll call him Bob, let us borrow his 3rd vehicle for a week so that the shop could take their time/test drives. Coy's Diesel found an air filter sensor unplugged with the wire laying across the exhaust manifold. With that plugged back in, it has made it through 3 of their test drives and 3 short runs for me tonight, whereas previously it failed 3x in a row. The theory was it could have overheated the wire to the point it was overheating the instrument cluster it plugs into which may have impacted the passive anti theft... will follow up with the report from there.
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post #7 of 8 Old 09-20-2019, 10:23 AM Thread Starter
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Died again, caught it in the act with the diagnostic tools in my hand and HPOP wouldn't build more than 180 psi. Shop has replaced IPR, to be determined whether it can make it a week or two without dying on us.
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post #8 of 8 Old 09-21-2019, 07:25 PM Thread Starter
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Over 100 miles the past two days, no issues.
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