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Ford Diesel cutting out {UPDATE}

Discussion in 'Off Topic Threads' started by freddy01, May 19, 2011.

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  1. freddy01

    freddy01 Member

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    My buddy has a 02 Ford w/ 160k miles. It is cutting out or staling when he hits a bump in the road. The dealer has never seen this problem before and wants to put in all new injectors. Problem started last week and the truck was running fine w/ lots of power.

    Anyone had this problem?

    Fred
     
  2. Russ-in-Pa

    Russ-in-Pa Well-Known Member

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    If it is the 7.3 liter engine, check/change the CPS (Cam Position Sensor).

    It is located at the front of the engine, and accessed from underneath. It takes 10-20 minutes to change, and should cost around $40-$50 for the part. The symptoms are similar to what you describe, and will get worse until it won't restart after cutting out.

    I would try this before getting into $$$injectors.
     
  3. kenf

    kenf Active Member

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    I doubt its the injectors, its more than likely the injector drive module, with the bounce causing some of the soldered circuits to move and disrupt the injectors firing.

    My other question would be is it still running fine with lots of power when it doesn't hit a bump? Oh, and is it a van or a truck? The van's had the module inside the drivers fender and they could collect water over time.
     
  4. Bvr Tail

    Bvr Tail Well-Known Member

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    Company I worked for had some of these trucks with similar problems.

    I believe they replaced some wiring harnesses to fix problem.

    Danny
     
  5. freddy01

    freddy01 Member

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    He has already changed the CPS. It is a F250 PU.

    We were thinking it has to be a loose electrical connection of some kind. The engine warning light is not on and it runs great until you hit a bump.

    He is just frustrated that dealer has not a clue.

    Does Ford have a web site for the dealer techs to share finds and fixes?

    Thanks for the input guys, Fred
     
  6. himark

    himark Well-Known Member

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    It is a wore through injector wire. common problem. It will short out intermittantly. Check the injector harnesses and you will find problem.
     
  7. jbbor

    jbbor Active Member

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    Injector wiring harness under valve covers! Jimmy Borum
     
  8. Tripod

    Tripod Well-Known Member

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    Iowa man!!
    I am with freddy1 on this one. worth checking out.
     
  9. Quack Shot

    Quack Shot Active Member

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    A good thing to have is a scan tool to watch what happens when it cuts out. Diesels have very different regulations regarding check engine lights. You can almost screw up half the emissions and the light would still be off. The "bump" thing has me thinking wiring harness or faulty component or connector. If you can get hold of a manual, there are some basic tests you can run to be sure.
     
  10. Bruce Specht

    Bruce Specht Well-Known Member

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    First things first, check the leads at the battery, use a dvom and start looking for an intermitten short or a loose ground wire. If that fails start the truck and carefully grab witring looms and move them back and forth and up and down till the truck cuts out. Simplest solution first place you look you have a bad connection somewhere.
     
  11. kenf

    kenf Active Member

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    Fred,

    If your Fred Dague, tell your friend to consider taking it to Solomon Ford in Brownsville on Rt. 40. They have a pair of the best diesel mechanics in the area there.
     
  12. Sam (ATA Noobie)

    Sam (ATA Noobie) Member

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    Dollars to donuts is UVCH.

    There is a large loom of wires that connects right in the dead center of each valve cover. If you climb up there, you can see them. They're infamous for working loose and cutting out over bumps. Some guys have even used pocket change to keep them together.

    Of course the stealershit wants the severl $k job of replacing perfectly good injectors. In the process, they will un/re-hook the harness up and claim the injectors fixed your problem.

    A google search of 'Powerstroke uder valve cover harness' oughta get you to some good, helpful articles. DO NOT let the dealership replace those injectors!
     
  13. DB3006

    DB3006 Member

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    Fred,
    Take the truck to a diesel repair shop that has the IDS scan tool. If you tell me where you are located I can locate and recomend a shop for you. More than likely it is the valve cover harness. The company I work for sells repair kits for this problem as well as many more parts for all the Ford Powerstrokes. We are located in Southern Wisconsin so if you are close by we can also diagnose and repair the truck for much less then a dealer.

    Dave
     
  14. warren

    warren Member

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    Change the fuel filter and check for water or other contanaments in the tank.

    warren
     
  15. sweeper1

    sweeper1 Member

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    check the ignition switch,sounds like the exact same problem I had.over the years the weight of the keys wore out the drum and when I hit a bump it would literally turn itself off.Many expensive fixes were proposed,sensors,injectors etc but check this firstsaved me a fortune
    Dean
     
  16. Dahaub

    Dahaub Active Member

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    Some of these suggestions warrant looking into. Then if you haven't found the problem you need to take the truck to a diesel specialist. Sheids Diesel Preformance is the guys to go to in my area. Look up on the net about preformance shops and you will get the guys who know diesels. You never know, the dealer might have a good mechanic but the preformance diesel shops do have good mechanics and they want your repeat business. They might even have a few toys to add to that truck the regular dealers don't carry. Dan
     
  17. freddy01

    freddy01 Member

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    Well, The problem is electrical but they haven't found it yet. But!!!! In the process of looking for it they found fuel in the coolant. Cracked fuel tube that cools the fuel prior to reaching the injectors. They have to pull the engine to replace all of them. Only one maybe bad but "it's a good idea to change them all". Needs a new oilpan, old one is almost rusted thru.

    Estimate of repairs.........................$4238.91

    Cheaper than a new Ford F250 truck @ $54,000.

    I had a 91 chevy 1500, sold it in 06, it had 172000 miles on it in 15 years. I bet I did not spend $5000 on it the whole time in tires, brakes and oil changes. Biggest expense was a brake booster @ 110000 miles.

    Thanks for all the input, guys. I will update when the job is done.

    Freddy
     
  18. cbxchris

    cbxchris Active Member

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    3 diesels was enough for me. EVERY one of them had issues before 100K. Last two 3/4 ton gas trucks I bought were trouble free well past the time the others had dumped on me.
     
  19. Sam (ATA Noobie)

    Sam (ATA Noobie) Member

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    Rusting oil pan SHOULD be a recall on those trucks. Every single one of them I've ever seen has had rusting problems. There are some products out there that would buy you another few years.

    Fuel in the coolant can be a number of things, including injector o-rings with no need to replace the actual injector. There's only a few places where fuel and coolant meet.

    Sounds like your buddy is getting taken for a ride. Dealerships have a tendency to do that.

    For $5,000 you could put new, aftermarket, more powerful AND fuel efficient injectors, a bigger turbo to go with said injectors.

    IDM is a good place to start, as is ICP. They are easy tests and while not cheap to replace, ANY of the above fixes would be cheaper.
     
  20. Russ-in-Pa

    Russ-in-Pa Well-Known Member

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    I traded in a 2000 F-350 7.3 crewcab dooley due to the oil pan rusting.

    I couldn't see putting $2500+ into a truck with 190k miles on it.

    Got a 2004 6.0 liter Excursion, and had it for 3 years, 150k miles and many $$ repairs.

    I am now done with Ford. Their failure to correct known problems with their (International's) diesel engines got me totally disgusted with them.

    Now driving an Isuzu 5.2 cabover diesel, and a Honda CRV for personal use.
     
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