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Discussion Starter #1
OK...it's been a "problem vehicle" from day one and the list of deficiencies is too long to post, however, the latest problem with my 04 F-250 Super Duty Diesel is this: The motor surges, sometimes stalls and intermittently runs rough like it's being fuel starved and the check engine light usually comes on. I've had this truck back to my dealer EIGHT FREAKING TIMES in the past 2 months and they obviously can't fix the problem. First 5 times they said it was the EGR valve, then they said it was the EGR valve wiring harness, then they said it was the Mass Air Flow Sensor. Ford customer service in Michigan is aware of the problem and I'm on the phone with them almost daily at this point. My question is this...and if anyone has any advice I'd greatly appreciate it...what do I do now? At this point, it's a safety issue as the truck has stalled out on me at critical times and I've almost wiped out because of the loss of steering and brakes.

So what does one do when one's Ford dealer cannot fix the problem and it has become a safety issue?

Can I push Ford to give me a new truck?
 

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Discussion Starter #3
where at in michigan are you??? PM me what dealer you are going to...
I'm in New York.

I'm in contact with the customer service reps at Ford in Michigan. They already sent out some technical grand poobah to look at my truck...and even HE couldn't figure out what was wrong.

From reading these posts I'm beginning to think it's the ICP sensor. Seems there are several posts complaining of the same symptoms I'm experiencing and the problem was the ICP sensor.

I'm taking the truck back AGAIN this Wednesday. If they can't fix it, then I'll insist they give me a new truck. This is now a safety issue.
 

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do you know what codes the truck is throwing when this occurs?
 

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Discussion Starter #5
do you know what codes the truck is throwing when this occurs?
No, I don't know the exact codes but I'm told by the service writer that the first 5 times the code said it was the EGR valve, which was replaced several times. Then they said it was the EGR valve wiring harness, which was replaced. Then they said the code said it was the Mass Air Flow Sensor, so they replaced that.

Bottom line is this, they don't know WHAT the hell is wrong with this truck. I even had the service writer drive me around and it stalled out on him while HE was driving it.

From reading many posts here, I seem to have the same symptoms others have had when their ICP sensor went bad.

Ideas?
 

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when does the truck stall? randomly? hammer down? idle?
 

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Can I push Ford to give me a new truck?

No......

ford is going to laugh at you if you ask them for a new truck. Im sorry to hear about your problems sorry i cant help you but im 99.9% sure ford wont do that. Good luck.
 

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You can eliminate the EGR valve possibility by simply installing a good valve and disconnecting the wiring harness to it.
 

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surging can be ICP, or sticking EGR, or sticking VGT Turbo, or Sticking IPR Valve. Without getting current codes and using proper scan tools and diagnostic routines, you are just throwing darts....
 

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Discussion Starter #10
Well, I'm dropping the truck off AGAIN tonight for the 9th time in about 2 months. They give me a free loaner truck every time, but at this point I'm really getting pissed that they can't fix the problem. What other recourse do I have if they just can't fix this truck?
 

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There is always the "lemon law". If I were you, PM Wriott. He had something similar happen to him I think. Or find a different dealer with a "certified Ford diesel mechanic" :dunno:
 

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Well, I'm dropping the truck off AGAIN tonight for the 9th time in about 2 months. They give me a free loaner truck every time, but at this point I'm really getting pissed that they can't fix the problem. What other recourse do I have if they just can't fix this truck?
Take to a dealer that can, or contact one of techs here and see it they can fix it at their dealer, or on the side.
 

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I am having the exact same problem as in the original post, except I have no check engine light. I have random surging and it will stall at random times and is really dangerous! Did you ever find out what was wrong??? Please Help!! - Mike
 
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