'03 Ford F350 6.0 PSD Issues

[jayste]

Well, recently I changed that dang old $100 OEM air filter apparatis on my truck. I no more did that and a few hours later I start getting a strange series of chimes. 5 chimes X 5 times. It'll do this for awhile and quit. After a while it'll do it again. Owners manual had nothing on it. The next day the check engine light came on. Yesterday I took it by Advanced Autoparts and they pulled a code (I don't know the number) and it termed it, "Injector pressure sensor malfuntion". Ok you guys lets here some ideas. I've also posted this on a PSD site and haven't gotten too much feedback. Any suggestions? It has 77,000 miles on it and is all stock. No aftermarket gadgets.

 

[Diamondpilot]

03's and early 04's were plagued with injector issues. Get it to the shop and have it checked over. There is probably a service note on it and the work will be covered.

As you may or may not know the injectors are hydraulic controlled by oil pressure. Did you change the oil at the same time you changed the air filter? Could be a issue with the oil you used or maybe a issue with the oil filter element.

Never heard of the chime thing.

Really get it to the Ford Garage asap. Just look over what that guy with the 2500 Dodge just went through with a simple issue. Not saying a dealer garage would not have made the same mistake but at least its the dealer screwing around with it.

Chris

 

[JohnnyW]

I just did the same thing for my truck. However, I have not had any issues in fact the truck ran a lot better. It is an 03 6.0 liter psd with a 6 speed manual F350 single rear wheel, crew. I would have a very reputable diesel mechanic check it out. The one I use started his own business after leaving Ford. Otherwise, go the local Ford garage especially if you are still covered by a warrantee.

 

[jayste]

Thanks guys for responding. I'm still weighing my options as the truck sits by the barn.

 

[Diamondpilot]

Thanks guys for responding. I'm still weighing my options as the truck sits by the barn.

You did not answer my questions. Did you change the oil at that same time???? With the injectors being hydraulic off of engine oil pressure that is where I would start looking.

I seriously doubt its the air filter. Maybe you knocked a wiring harness or something?

Chris

 

[jayste]

You did not answer my questions. Did you change the oil at that same time???? With the injectors being hydraulic off of engine oil pressure that is where I would start looking.

I seriously doubt its the air filter. Maybe you knocked a wiring harness or something?

Chris

Sorry Chris, I forgot to respond to the first part of your reply. No, I didn't change the oil at the same time. I usually do but the last time changed the oil I put it off until now. I'd have to go back a take a look as far as the wiring harness is concerned. I could have knocked it around. The only thing I did take loose was the coolant resevoir because it's usually right in the way but usually I just take the bolts out and slide it to one side and leave the hoses attached.

 

[Diamondpilot]

Jay

Get it to the dealer. Like I said there were issues with cut o-rings on the injectors on the 03-early 04 6.0's. I bet it will get fixed easily at no charge to you.

While you are at it check the oil level. If its been a while change it. You may just have a oil coaking problem. The 6.0's love to be run hard. Everyone I have heard of with issues say they baby them.

Good luck!

Chris

 

[Soundguy]

I have an 04 6.o psd.. it runs great.. I make alot of trips out of state to grab tractors.

i also have installed an aftermarket air filter housing.

no issues on the injectors, though recently I changed the diesel fitler under the hood and had to go thru 2 orings before I got it to quit leaking. early when i first had it I also had a problem with an oem oil filter oring that leaked.. i now use napa oil filter and air, and diesel fitler elements with -0- issues.

other than that. just puit 2 new batterie sin it today as the old ones were neairng 5ys old and getting weak.

I run motorcraft 15w40 psd oil in it.

soundguy

 

[63DH8]

I have an 04 F-250 with a 6.0 diesel that is completely bone stock. Yesterday, I drove from Tacoma, WA to south of Portland, Ore and back to retrieve a CK-35 Kioti tractor, loader, backhoe, and brushhog. The stock 6.0 had no problem pulling the trailered tractor with extras up hills doing well over 75 mph with plenty of pedal left.

International admitted they may have underdesigned the engine when they built the thing with only six headbolts per cylinder, so adding anything that'll make the engine produce more power may not be a good idea. Stock, the engine produces more power than what most people realistically need. Try to squeeze much more power out of it, and you're going to start seeing problems. If you ever have to have the heads pulled, have the headbolts replaced with studs. That'll help make the engine more reliable.

btw... check out the Ford Truck Enthusiast site. There's many experts and a handful of Ford engineers and mechanics there who are more than happy to help.

 

[devildog1]

On my 2005 PSD I too have changed the OEM stock filter housing. I completely removed the whole system and changed it for a Injen Cold Air System which includes a Amsoil one million mile secondary air filter. Have towed my 34' Holiday Rambler across the USA a few times with no issues at all. Check out your wiring and or your air sender to make sure everything is connected tightly.Like others have said, the 6.0 does not ever lack for power.
DevilDog

 

[Mike Costello]

The stock air filter on the 6.0 engine can be fickle to R/R. Make sure it is installed correctly & securely (no air leaks). Check all nearby wiring,sensors, etc. just in case something was knocked loose.
You can also go to your local auto parts dealer and run a scan with their OBD ll test unit. Most will let you use it for free in their lot. Just hook it up to the serial port and follow the onscreen instructions. Write the codes down that it reads. Then go home and do a search on your computer using the code numbers you pulled... such as Ford Pxxxx. You will then have an idea of what needs to be done.
After the fix, you can clear all the codes by disconnecting all batteries for about 30 minutes or use their OBD ll tester to clear the codes.

 

[Soundguy]

I have an 04 F-250 with a 6.0 diesel that is completely bone stock. Yesterday, I drove from Tacoma, WA to south of Portland, Ore and back to retrieve a CK-35 Kioti tractor, loader, backhoe, and brushhog. The stock 6.0 had no problem pulling the trailered tractor with extras up hills doing well over 75 mph with plenty of pedal left.

.

Same here, I just made a trip into NE GA from central FL to grab a tractor, before that, went to lousiana for one, and my previous trip was a 40 hr red eye into central texas. all pulling a 16' trailer empty one way, and laoded with a tractor the other. absolutely no power issues at all. Made the trip a whole lot better than my dodge 5.9l gasser would have.

soundguy

 

[jayste]

Well guys here's an update. I've been reading on the web and am seriously considering changing out the ICP sensor and maybe the pigtail connector. These will probably run in the $175-275 range depending if I need one or both. Problem is my year model and the location of the sensor. It's on the DS of the engine at the back behind several parts. Some say go from on top and take parts off to get to it and some say go from the bottom and reach up. One other thing is I'm debating going ahead and putting it in the shop to have the "Inductive Heating Reprogram" done. I'll have that charge anyway but thought I'd save the other and do it myself and hope this does the trick...Comments?...

 

[Diamondpilot]

Well guys here's an update. I've been reading on the web and am seriously considering changing out the ICP sensor and maybe the pigtail connector. These will probably run in the $175-275 range depending if I need one or both. Problem is my year model and the location of the sensor. It's on the DS of the engine at the back behind several parts. Some say go from on top and take parts off to get to it and some say go from the bottom and reach up. One other thing is I'm debating going ahead and putting it in the shop to have the "Inductive Heating Reprogram" done. I'll have that charge anyway but thought I'd save the other and do it myself and hope this does the trick...Comments?...

With as much as these trucks cost and how complicated they are I would let the Ford Shop do the work. Sounds like it has been a good trouble free truck for you up to this point. Taking a 7 year old truck to the shop only makes since and have it checked over. Spend a little money on it and it will last you a long time. Heck, it may still be under warranty and like I said there were many service bulletins on the early 6.0's like you have and it may be covered under warranty.

Chris

 

[jayste]

With as much as these trucks cost and how complicated they are I would let the Ford Shop do the work. Sounds like it has been a good trouble free truck for you up to this point. Taking a 7 year old truck to the shop only makes since and have it checked over. Spend a little money on it and it will last you a long time. Heck, it may still be under warranty and like I said there were many service bulletins on the early 6.0's like you have and it may be covered under warranty.

Chris

You know Chris, just yesterday I was wondering the same thing as I read some info on the web. I'm not the original owner and Ford doesn't have me and my address on record as the owner of this truck. I might have missed out on some information they would have sent out. But I guess that would only include recall stuff..? Not service updates and all. What do you think?

 

[Diamondpilot]

You know Chris, just yesterday I was wondering the same thing as I read some info on the web. I'm not the original owner and Ford doesn't have me and my address on record as the owner of this truck. I might have missed out on some information they would have sent out. But I guess that would only include recall stuff..? Not service updates and all. What do you think?

Take it to the dealer and pay them to check it out. Talk to them first and set a cap in $$$ on the work they can do. My local Ford Garage will do a oil change, rotate, check all lights ect, run it on the computer, and check the vin for outstanding stuff for something like $50. It will cost more for a Diesel but talk to them. We did this on a Navigator my buddy bought of the net. Good piece of mind and worked as a pre purchase inspection for him. They even took us in the shop while it was on the lift so we could look it over.

Chris

 

[jayste]

Ok. Here's the skinny. I took my truck to local Ford dealer and here's what they're telling me. When the truck is cold the injectors are "dropping out". SOOOOO, they want to put a new ICP sensor on it, a new high pressure pump and EIGHT, yes I said EIGHT (reman) injectors in it so thats- 169.50+336.30+8@312.32=3004.36+1600 labor and 255.37 for big brother and that's a grand total of $4859.73:confused2::confused2:

Needless to say I paid my $149.95 for the diagnostics and left. Well not exactly that way but I'll be nice now.

What do you think for a truck with 78000 miles, yes, that's seventy-eight thousand not 7 hundred and eighty thousand?!

 

[Diamondpilot]

About the same issue with my neighbors 2007 Duramax with 45,000 miles. They want $1400 to change just 2 injectors.

I would have them start by putting on the ICP sensor, resetting the computer and give it a try.

I may have them also change the pump if they can prove its faulty but probably would just try the ICP first. You can always bring it back.

These things are expensive. I can not believe it needs all that. I would take it somewhere else and get a second opinion.

Chris

 

[jayste]

About the same issue with my neighbors 2007 Duramax with 45,000 miles. They want $1400 to change just 2 injectors.

I would have them start by putting on the ICP sensor, resetting the computer and give it a try.

I may have them also change the pump if they can prove its faulty but probably would just try the ICP first. You can always bring it back.

These things are expensive. I can not believe it needs all that. I would take it somewhere else and get a second opinion.

Chris

Chris, that's exactly what I'm going to do. I only took it to Ford to take advantage of any "factory updates" and whatever they might have on it. I've got a good garage that I usually take my trucks to have the heavy stuff done at. I'm scheduled to take it there on Monday.

 

[Ryan03]

Ok. Here's the skinny. I took my truck to local Ford dealer and here's what they're telling me. When the truck is cold the injectors are "dropping out". SOOOOO, they want to put a new ICP sensor on it, a new high pressure pump and EIGHT, yes I said EIGHT (reman) injectors in it so thats- 169.50+336.30+8@312.32=3004.36+1600 labor and 255.37 for big brother and that's a grand total of $4859.73:confused2::confused2:

Needless to say I paid my $149.95 for the diagnostics and left. Well not exactly that way but I'll be nice now.

What do you think for a truck with 78000 miles, yes, that's seventy-eight thousand not 7 hundred and eighty thousand?!

Sounds like you need a second opinion. I am not a factory trained Ford Tech, however I am an ASE certified master truck tech with 14 years of Diesel fleet experience. Most of the time, the high pressure pumps are replaced due to leakage of engine oil from the pump into the valley of the engine, and down the bell housing to the ground. This is often mis diagnosed as leaking valve covers. In the beginning, this leak is just annoying, but as time goes on, it will turn into a rough running after a cold start due to air entering the High Pressure oil system, then as more time passes be accompanied by excessively long cranking times, combined with rough running for the first few minutes of run time until the air bleeds out. These are all signs that the HP pump is on its way out. Shine a flashlight down into the engine valley in the very front of the engine between the cylinder heads, Do you see any oil puddles in the valley ?.

I normaly access the ICP from the top, but to each his own. In my experience, HP pump failures are more common than ICP failures. What codes were retreived from the truck, what did the dealer say the HP pump oil pressure was during cranking, idling, and high boost.

I just tore down a 2002 7.3 today at work to replace the HP pump. It currently is torn down in my bay, if you would like, I could take some pics of the old and new pump, as well as where it is at. I realize it is a 7.3, not a 6.0, but it might give you a better idea of what you are looking at.