Help w/rough start 04 Xcursion

[rcgrissom]

Newbie. Just registered. I am desparately searching for help to solve rough start issue with my 2004 Ford Excursion 6.0L diesel. Please bear with me with this long post, but need to provide background to issue and what work has been done to try to solve the problem. Let me say up front....thanks so very much to anyone who posts suggestions/recommendations how I might solve this problem...short of blowing it up! (Location: Atlanta, TEXAS)

BTW...I know just enough about diesel engines to be dangerous! I'm a a so-called jack of all trades...master of none. Tell/show me how to do it and I don't mind attacking the issue.

Have had cold start issue for more than a year now. Cold start also includes warm start where truck it left to sit with motor off for an hour or so. When starts, have same issues, although not as severe as a full cold start.

Truck will start, but sounds terrible. Sluggish, chugging, sounds like cylinder missing or something. If you try to drive before five minutes or so of idling, the truck won't hardly move. You can push the fuel pedal to the floor and nothing happens. One truck warms up, it's like nothing is wrong. Note: mileage is not what it used to be.

Work performed to try to solve problem: Have used a diesel mechanic from dealership since truck was new. In past year, he's replaced 10 fuel injectors (one trip he replaced all 8 injectors, remanuf.) Replaced turbo two months ago.

Frustrated, carried to another dealership and they replaced fuel pump and reprogrammed FICM to "new" set. When picked up truck, it starts better, sounds smoother. Still a bit sluggish, though. But worse...there was a 1.5 second delay in fuel pedal response all the time...hot or cold. This was unacceptable and possibly dangerous when driving in heavy traffic. Called dealer and they said it does that to protect the turbo. Crock!

Trying to troubleshoot, I remembered I had a Superchips Flashpaq program unit I've not used for some time. (Had been running stock for months.) Attempted to change program on truck, but due to new "Ford" program, the unit had to be updated. Did this online, then added the performance option to the truck. Low and behold, the lag time on accelleration is gone! Still have the rough start issue, but not as bad as it was a month ago.

Searching online, I found a post ford-trucks.com about testing FICM. Symptoms sounded just like issues I am experiencing. I thought...had to have bad solder points on the FICM. Well this morning, I tested the FICM with a multimeter as outlined and all readings were just where they should be. So guess the FICM is okay.

Original head gaskets, etc. No after market motor modifications.

I've spent close to $8,000 at two dealerships in the past year trying to get this issue resolved. Stupid, yes, but remember I'm not a professional mechanic so I have to rely on others saying they can fix my problem. ALSO, the Excursion is paid for and they don't make em anymore.

Found PHP's website after testing the FICM this morning and wondered if a custom program would solve the issues I have. Or are there other things going on here. If anyone has any suggestions please let me know. I am whacked out and don't really know what to do next!!!

BTW...when I plugged in the flashpaq I ran diagnostics and it gave me these error codes: P0275 cyl 5 contribution/balance fault; P0401 Exh. gas recirc. flow insufficient delete; P0603 internal ctrl mod kam error.