6.0 PowerStroke and TorqShift Bulletins
6.0 PowerStroke Calibration Update History link
6.0 PowerStroke and TorqShift Bulletins

Updated: 6-16-04

Harsh or Delayed Forward or Reverse Engagement:

This could be caused by a sticking line pressure control (PC-A) solenoid. Typically the line pressure will be fluctuatiing wildly (up to 500 PSI!). To service, replace the line pressure control solenoid with P/N 4C3Z-7G383-AA. Broadcast Message 1586

This repair will require removing the solenoid harness, so a new harness sealing o-ring will need to be installed. In some cases the solenoid body will need to be removed from the trans to remove the harness and solenoid. In this case the solenoid body gasket will be needed as well. Note: Do not loosen the 10mm head bolts on the solenoid body. Only loosen the 8mm head bolts.

Sepentine Belt Noise:

Engineering is investigating this condition, and a repair is expected this summer. Broadcast Message 1321.

Exhaust Leak/Hiss Noise:

Some trucks may exhibit an exhaust leak at the driver side turbo inlet Y pipe. This usually occurs at the flex bellows portion of the pipe, and may be due to misalignent of the pipes. Replace the inlet Y pipe, following the new service procedure (also found in droan noise below). Broadcast Message 1419.

Failed factory Y pipes should be returned to International for inspection. Failed replacement Y pipes, or replacement pipes that will not line up properly should be returned to Ford's North American Diesel Team (contact HOTLINE for details) for inspection.

6.0 Moan/Droan Between 1500-2000 RPM:

Engineering has investigated this condition and found the cause to be engine firing pulses causing the turbo mounts to vibrate/resonate. There is a revised turbo pedestal for trucks built before 9-30-03--P/N 3C3Z-6N639-BA. Ensure the droan is not caused by a bound exhaust system. Inspect for any damaged or broken exhaust hangers. Check the turbo downpipe by loosening the pipe at the top and bottom, checking its alignment and retightening. If the droan is still present, check the part number embossed on the turbo pedestal just below the turbo compressor outlet to the intercooler. If the number IS NOT 1846207C1, replace the pedestal with the above part. After replacement, or if the number IS 1846207C1, loosen the turbo inlet pipes and EGR cooler flange and neutralize by installing the components in this order: snug the flange between the LH and RH inlet pipes; torque the EGR cooler clamp to 53 in/lbs; torque the pedestal bolts to 23 ft/lbs; torque the turbo inlet clamp to 9 ft/lbs: snug the inlet pipes to manifolds. Ensure all components are properly aligned. Torque the flange between the LH and RH inlet pipes to 20 ft/lbs and the inlet pies to the manifolds to 20 ft/lbs. Broadcast Message 0992, SSM 17530, TSB #04-9-4.

Shorted Fuel Injection Control Module: Some trucks may continue to run at idle after the ignition is shut off, and the instrument cluster may stay on. This may be caused by an internally shorted FICM. To shut off the cluster and engine remove the FICM relay in small auxiliary relay box near the brake master cylinder. To prevent battery drain disconnect the batteries. Replace the FICM to correct this condition. SSM #16749.

Radio Interference with Head- or Parking Lights On:

To diagnose this condition, try operating the power mirrors. Disconnect whichever mirror causes interference and try actuating the switch again to confirm the noise is gone. Replace the mirro cover to correct the condition (base part number 17D742 or 17D743). Broadcast Message 1304

Manual Transmission Fluid Leak:

This may be mistaken for a rear main seal leak. To diagnose, add florescent dye to the transmission and test drive the truck. Inspect the transmission for leaks with a UV lamp. Broadcast Message 1490.

High Pressure Oil Standpipe Service:

On engine built before 9-29-03, if the standpipe running up through the head(s) to the high pressure oil tube is remove, it will need to be replaced. On engines built on or after 9-29-03 the o-ring on the standpipe xcan be replaced and the pipe reused. Broadcast Message 1426.

Clunk or Pop from TorqShift at 2-3 MPH:

A clunk or pop may be heard or felt on drive away after starting the engine, backing up and shifting to drive, usually around 2-3 MPH. This condition may be intermittent. It is the result of normal backlash (movement) between the splines on the low/reverse one-way clutch. Broadcast Message 1335

Oil Level Check Tip:

When checking the oil level on the 6.0, the vehicle must be on a level surface and the dipstick must be fully seated into the tube to ensure an accuarte reading. Do not add oil if the level is above the "MIN" line on the dipstick. Broadcast Message 1512, 1574.

ESOF Transfer Case Concerns:

On some trucks with the electronic shift-on-fly transfer case there may be engagement/shift concernes. Check the ESOF motor relays on the driver side fender. If the relays or relay box have become dislodged, corrosion may form on the relay terminals or inside the relays. Broadcast Message 1511

Lack of A/C Cooling at Highway Speeds/Rapid Compressor Clutch Cycling:

This may be due to low suction pressures causing the A/C compressor clutch to cycle too rapidly. Recover the refrigerant from the system and recharge with 56 OZ on single A/C and 64 OZ on dual A/C vehicles. Broadcast Message 1369.

Dual Mass Flywheel Applications:

F250/350 trucks with the 6 speed manual transmission built before 12-1-03 are equipped with a dual mass flywheel. All F-Series trucks built after that date with the 6 speed have single mass flywheels. Some F-450/550's built before the above date may have dual mass flywheels, too. When replacing, use only the same type parts that were originally installed on the truck. Broadcast Message 1472.

TorqShift Harsh/Slipping Engagements, Upshifts, and/or Downshifts:

If these symptoms are experienced after the batteries have been disconnected, then it is due to the transmission adaptive strategy being cleared from the computer. This may occur when the vehicle is delivered new from the factory as well. Warm the engine and transmission to operating temperature. Perform three series of upshifts at light, medium and heavy throttle. Perform three sets of gear engagements (N-R, N-D, D-R, R-D) with the brake pedal firmly depressed and waiting three seconds between each engagement. Peform these steps once in normal mode and once in tow/haul. Broadcast Message 1196

2003/2004 Fuel Economy:

Ford vehicles equiped with the 6.0 PowerStroke diesel are not rated for fuel economy by the EPA. If economy is in question, a boost test should be performed. If boost reaches 22-25 PSI in third gear, wide open throttle under load, then th engine s operating normally and no economy related repairs need to be performed. If not in specs, then the engine will need to be diagnosed--check sensor reading, VGT and EGR operation, fuel pressure and quality, crankcase pressure, intake or exhaust restriction, exhaust or CAC leaks.

Fuel economy will be affected by many factors, including: excessive idle time (one hour equals approxmately 33 miles of driving), fuel quality and blend, ambient temperature, driving habits, vehicle use, towing, loads, add-on accessories. Broadcast Message 1271

Oil Leaks from Lower Engine Area:

Some 6.0 engine may exhibit an oil leak that appears to be coming from the lower crankcase (bedplate), upper or lower oil pan, rear main seal, or front or rear covers. First inspect the cam and crank position sensors to ensure the leak is not the o-ring on one of these sensors. If the sensor(s) is wet, remove it and replace the o-rings. Cam sensor (driver side): 3C3Z-9N693-HA and -JA; crank sensor (passenger side): 3C3Z-9C064-DA.

An oil leak may occur at front or rear covers if they were removed without cutting the sealing joints behind them. Broadcast Message 1268

Vacuum Pump Inop or Ventilation System Deverts to, or Only Blows Through, Defrost Vents:

If the vents devert to the defrost mode, this is usually due to a leak in the vacuum system. Typically if the problem is in the automatic hub system, this will only occur when 4X4 is selected. If it occurs on in a specifc ventilation mode, the vacuum servos associated with that selection would be suspect. If the ventilation system stays on defrost at all times, a leak in the system at the vacuum pump, or the vacuum pump itself may be at fault. For vacuum pumps that are inoperative or continuously running, replace with P/N 4C3Z-2A451-BA. Broadcast Message 1244, 1575

Oil Leaks from Front and/or Rear Crank Seals:

If an oil leak has been verified as coming from either the front or rear crankshaft seals, the crankshaft end play must be checked to ensure it is 0.020" or less. If within specs, replace the seal using the correct tools and procedures. Broadcast Message 1240

2004 F-Series/Excursion Lack of A/C Cooling:

Trucks built between 12-1-03 to 1-26-04 may have strands of insulation trapped between the compressor and refrigerant line manifold. The system will need to be recovered and the the insulation removed from the joint. The tube and manifold assembly (4C3Z-19D850-CA) may be reused if it is undamaged, but the o-rings (1F1Z-19E889-AB) should be replaced. Broadcast Message 1118.

2004 Econoline Cut-Away Cab Driveability Concerns:

Some vehicles built before 2-27-04 may experience low engine RPM and/or other driveability concerns after a long deceleration in manual second or third gear. To correct, reprogram the computer to the lastest availabe calibration. Broadcast Message 1124.

03/04 F-Series/Excursion Cam and Crank Sensor codes:

Some trucks may exhibit a variety of driveability concerns with camshaft (CMP) and crankshaft (CKP) position codes P2614 and P2617 stored in the computer. If both of these codes are stored along with other codes, those other codes should be diagnosed first. f these two codes are stored with no other codes they should be disregarded and the concern should be diagnosed by symptom. For example, a chaffed FICM harness or no fuel pressure can cause both of these codes to be set together. Broadcast Message 1150, 1301.

03/04 TorqShift Solenoid Body/Solenoid Harness Application:

If the TorqShift solenoid body needs to be replaced, the new body may come with a missing pressure sensor. If the harness needs to be replaced it may come missing a connector for a pressure sensor. The input from the sensor in question was deleted from the TorqShift programming and is no longer used. The replacement parts an not incorrect and may be used. Broadcast Message 1151.

03/04 F-Series Overheating with Snow Plow Installed:

If a snow plow is installed on a truck with the 6.0, it may disrupt the air flow through the front of the truck causing the cooling fan to stop or turn in reverse. For trucks with snow plows there is a revised fan clutch available (P/N 4C3Z-8A616-SA). Some trucks have been modified with a jumper on the fan connector to keep the fan continuously engaged. This jumper must be removed before connecting the new fan. Broadcast Message 1137.

ICP/EBP Sensor Repair Kit:

Both PowerStroke engines may exhibit codes related to the ICP(7.3: P1280; 6.0: P2285) and/or EBP sensors (P0472). If these codes are present, clear them. Start the engine and wiggle the sensor connector that matches the stored code. If the code returns, replace the sensr connector--P/N 3C3Z-12224-BA for 94-96; 3C3Z-12224-AA for 97-2004. Broadcast Message 1078/SSM #17573.

Trouble Codes P0603 and/or P0605:

Some PowerStroke trucks may exhibit codes related to keep alive memory--KAM (P0603); or read only memory--ROM (P0605). P0603 may be set if the batteries or computer are disconnected. On the 6.0 the computer should be reprogrammed with the latest available calibration. Broadcast Message 1076.

TorqShift Gear Trouble Codes:

When diagnosing a TorqShift transmission, trouble code P0700 may be stored. Diagnose using any additional stored codes. P0730 may be found stored with codes P2700-2704. Use the additional code(s) to determine which clutch or clutch control is causing the gear ratio P0730 code to be set. Broadcast Message 1158, 1525.

FICM Replacement:

When replacing the fuel injection control module (FICM), the new FICM will need to be programmed after installation. Replacement FICM's are shipped unprogrammed and have to be programmed to match the exisisting computer. Broadcast Message 1171.

Shudder on Acceleration:

On trucks with single driveshafts, check the rear axle spacers. If the spacers are installed with the thin side (1 7/8") facing forward, they should be reversed (swapped left to right) so the wide side (2 1/4") faces forward. If the truck now only shudders with a load, swap out the spacers with 2" flat ones from an F250 long wheel base (two-piece driveshaft), P/N 2C3Z-5598-PA.

6.0 Reprogramming Errors:

If you encounter any errors wihile attempting to reprogram the PCM, FICM or TCM, exit the session on WDS in completed status, not delete. Ensure the vehicle battery is fully charged and the WDS sofeware is up to date. If there is a no communication/no start condition, reboot the WDS. When WDS restarts, go to previous sesions and select the vehicle you had saved and perform the programmable module installation function for the PCM only. If unresolved, contact HOTLINE. Broadcast Message 1064.

Low Power/No Boost and/or Code P2263:

If the turbocharger is suspected to be the cause of low boost, it should be tested by manually activating the variable geometry turbo control valve. The engine should be at operating temperature. Using the WDS active commands in datalogger, monitor EBP, VGT%, RPM abd MGP. Set the RPM to 1200 and the VGT% to 0 and record the EBP and MGP readings. Increase VGT to 85% and watch for an increase in EBP and MGP, and listen for a whistle from the turbo. If there is no pressure increase or whistle, check the control wiring for the VGT by installing a est light in the VGT harness and commanding the VGT from 0-85%--the light should be off and then slowly brighten. If the wiring checks out, replace the VGT control valve (P/N 3C3Z-6F089-AA) and retest. If the condition is unchanged, then replace the turbocharger. Broadcast Message 0887.

Engineering is currently investigating false P2263 codes. Broadcast Message 1290

Normal EGR Valve Operation--Open at Idle:

Trucks built after 9-30-03 and those truck reprogrammed with WDS version 27.9 or higher will now have the EGR valve open at idle. This is to reduce engine noise at idle that has occured from removing the pilot injection. When diagnosing the EGR valve it is normal for the valve position value (EGRVP) to not change until the EGR duty cycle is greater than 30%. Broadcast Message 1067.

False Codes Set During Active Command Testing:

When performing active commands on the EGR, IPR, and VGT, trouble codes associated with those components may be generated. Disregard codes for these components that result from active caommand testing and be sure to clear all continuous memory codes after testing is complete. Broadcast Message 0962.

Various Driveability Concerns, Harsh 3-2 Downshift/Clunk, Trucks Built after 9-30-03:

Trucks built from 9-30-03 to 2-8-04 may exhibit excessive smoke, rough running or misfire after extended idle or poor performance after a cold start, typically at altitudes above 5,000 feet, rough or rolling idle or white smoke on hot restart, rough or rolling idle immeadiately following a cold start, DTC P0500 (no vehicle speed input) on manual trans, or DTC P0299 A harsh 3-2 downshift or a buck/jerk on accelerator tip-in/tip-out in tow/haul mode or a harsh reverse engagement at low mileage may also be present. To correct, reprogram the PCM, FICM and TCM with WDS version B29.4 or higher. Broadcast Message 1019/1167.

Related to:

White/gray Smoke, Cold Start Performance Issues, Harsh 3-2 Downshift:

Trucks built before 9-30-03 may exhibit excessive smoke, rough running or misfire after extended idle or poor performance after a cold start, typically at altitudes above 5,000 feet. A harsh 3-2 downshift or a buck/jerk on accelerator tip-in/tip-out in tow/haul mode may also be present. To correct, reprogram the truck's computers with Running Change 7. Broadcast Message 1364; SSM #17437

Low Charging System Voltage Under High Load Conditions--Single Alternator Trucks:

Some trucks with single alterantors may exhibit low changing syatem and battery voltage during high load conditions, such as plowing snow, spreading salt, or running lighting. If the condition occurs only when running these added accessories, there is a 140 amp replacement alternator available--P/N 4C3Z-10346-BA; that may be purchased. Keep in mind the effectiveness of the larger alternator will vary due to component age design and use. Broadcast Message 1036.

2003-2004 Oil Leak from Head Gasket:

Some engine may exhibit what appears to be an oil leak from the head gasket. Since there is no pressurised oil at the head gasket, a leak at this location is unlikely. Inspect the following area instead: turbo oil feed and return, oil cooler, HP oil pump cover, ICP sensor, IPR valve, valve cover gasket, rocket carrier gasket, Injector and glow plug ports and crankcase breather port. Use florescent dye and an UV lamp to pinpoint the source of the leak. If the leak is from the head gasket, the head should be removed and it and the block checked for flatness. Broadcast Message 0873.

Ford's Position on Biodiesel:

Ford is advising that any of their vehicles powered by a diesel engine, regardless of manufacturer, may exhibit engine or fuel system problems when using fuels with greater than 5% Biodiesel. Any problems when using fuels containing more than 5% Biodiesel should be referred to the fuel manufacturer. Ford only recomends using fuels containing no more than 5% Biodiesel (B5) in their diesel powered vehicles. In addition, as per World Wide Fuel Charter (WWFC) catagory 1-3, fatty acid methyl esters (FAME) must meet EN14214 and ASTM D 6751 specifications. Broadcast Message 0884.

Emissions Recall 03E03:

The federal government requires that all vehciles built from 1996 have the ability to be diagnosed by aftermarket scan tools. This is to ensure that all vehicles meet emission standards without the owners being locked into going to the dealership for repairs. This was addressed by the programming update described under Running Change 5 back in August, but now it is a manditory update.

Since RC5 has been superceded by RC7, this means all vehciles subject to this recall will have increased engine noise at idle due to the deactivation of the pilot injection in the split shot strategy.

TorqShift Harsh Disengagement Shifting from Reverse to Park:

Some trucks built before 11-14-03 may exhibit a harsh disengagement when shifting the TorqShift transmission from reverse to park. A cluck may also be heard. To correct, remove the control body and replace the manual valve with P/N 4C3Z-7D376-AA. Insert the new valve into the body plugged end firts. Install a new valve body gasket, P/N 3C3Z-7C155-DA. Broadcast Message 1219.

A/C Compressor Cut-Out above 1500 RPM after Battery Disconnect:

Part of the computer's strategy it to disable the A/C above 1500 RPM after power has been interupted to the computer. If the batteries are disconnected for any reason, the engine should be started and shut off to reset the A/C strategy. The A/C will work normally on the second engine start. Broadcast Message 1316.

Cold Temperature Lack of Power, Poor Economy, Hard Start, Excessive White Smoke:

This could be due to gelling of the fuel, formation of ice in the fuel tanks or lines or poor fuel quality. If diagnosis finds no cause for the above symptoms, try using a fuel conditioner, such as Stanadyne Performance Formula or equivalent, that will improve the cetane level of the fuel. Do not use any product containing alcohol. If the conditions improve with the additive, then find another fuel source or continue to treat the fuel. Broadcast Message 1309, 1464; SSM #17406.

Water Injestion/Snow Packing/Ice Build-Up in the Air Induction System:

Some trucks equipped with a 6.0 engine may exhibit a trouble code P0103 for the Mass Air Flow sensor circuit. This may be due to water or snow getting into the air cleaner assembly or ice building up in the air cleaner. The check engine lght will only illuminate on Califronia emissions vehicles. To service, check the air cleaner for restrictions, inspect the filterminder and MAF sensor for damage and/or loose wires or damaged/corroded terminals. The MAF sensor should be diagnosed before replacement. Broadcast Messages 1000, 1103.

Fuel Pump Trouble Code P0232:

Some trucks may store a trouble code for the fuel pump secondary circuit being high. Diagnosis may lead to replacing the PCM (computer). Before replacing the PCM, check the ground at the driver side upper firewall area for loose connection or corrosion. Remove the grounding screw and check for rusted threads. Correct any problems, if found. If no problems are found, continue with normal diagnosis. Broadcast Message 1110.

Intercooler Hose Blow-Off:

If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. To service, replace the hot side intercooler pipe/hose assembly. Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoeses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off. Broadcast Message 1099.

Single alternator trucks: 4C3Z-6C646-BA

Dual alternator trucks: 4C3Z-6C646-CA.

On 2004 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, this may be due to the clamp being under torqued or damaged. Clean the outside of the intake manifold inlet and the inside of the hose or pipe. Inspect the clamp, and if it is damaged, replace it (trucks built from 12-15-03 to 4-1-04, P/N 4C3Z-6F081-AA; built after 4-1-04, P/N 1C3Z-6K786-BA). Seat the hose/pipe onto the intake manifold and torque the clamp (6 ft/lbs 12-15-03 to 4-1-04; 9 ft/lbs after 4-1-04). Broadcast Message 1329. Rear Main Seal Leak:

Some trucks with the 6.0 may exhibit what looks like an oil leak from the bellhousing, presumably for the rear main seal. This actually may be excessive grease from the torque converter pilot melting and runing out of the bellhousing. It is recommended that 3 ounces of florescent dye be added to the oil, the truck driven, then the leak inspected with an UV lamp. If dye is detected, the engine should be inspected for leaks on top that may be running down the back of the engine. If no upper leaks are detected, replace the rear main seal. Broadcast Message 1017

Low Lube Oil Pressure:

Some 6.0 engines may exhiit low lube oil pressure caused by leakage in the high pressure oil system. To determine if this is the case, remove the oil filter and hold down the oil drain valve on the left side of the filter housing with a screwdriver. Watch for oil flow with the engine cranking. If flow is present, diagnose the HP oil system for leaks. If no flow is present, diagnose the lube oil system. Broadcast Message 1044

6.0 Injector Removal/Installation:

It should be noted that injector serve on the 6.0 is different than on the 7.3. No air tools should be used in removal or installation of the injectors to prevent damage to the injector. A T-40 Torx bit with a minimum shaft lenght of 2" is require to ensure proper torque of the injector (24 ft/lbs) and to prevent the drive tool from contacting the injector and damaging it. New o-rings and combustion seals should be used any time an injector is removed. Care should be taken when installing the high oil pressure rail to prevent damage to the upper injector o-rings.

TSB# 03-20-10

6.0 Programming Update:

Another update has been issued for the 6.0 as of 10-3. This update is to correct the loping idle on hot start, poor acceleration on cold start, and to correct false codes related to PCM-FICM compatibility and slow oil warm up, and enhanced turbo performance code diagnosis. TSB 03-20-12.

Wiring Harness Chafing:

Some 03/04 trucks with the 6.0 may exhibit a crank/no start, rough running, misfire, buck/jerk or lack of power. This may be due to the FICM harness chafing on a valve cover stud near the FICM. Other potential locations for chafing are where the harness routes past the EBP sensor, the belt idler on the driver side of the engine, the glow plug control module bracket on the passenger side of the engine, and the accelerator pedal sensor wires at the steering column (adjustable pedals only). Reroute and repair the harness as necessary. Broadcast Message 0918/1374, SSM #17522.

Flutter Noise on Deceleration:

Some 03/04 trucks may exhibit a fluttering noise from the air filter assambly on deceleration. This is a characteristic of the engine and posses no problems with the engine or turbo. No repair should be attempted. Broadcast Messages 1046

Emissions Recall on 2003 F-Series 6.0:

Certain 2003 F-Series trucks built at the Kentucky Truck Plant between 6-6-02 through 6-8-03 require replacement of the engine emissions lable on the right valve cover. Ford will send new lables to owners who have trucks to which this recall applies. You can bring the turck into any Ford dealership to have the label affixed, or do it yourself. This recall does not apply to California emissions vehicles below 14,000 GVW. SFA 03L12.

Programming update for 2003/04 6.0 PowerStroke: As of 8-8-03 there has been a new calibration for the 6.0 PowerStroke. This calibration was not installed in trucks built before 8-18-03. This update is supposed to address rough idle/surge/smoke at light throttle application, improved A/C performance at idle, minor manual transmission lauch performance, smoother downshift in tow/haul at 20 MPH, improved performance at low altitude/high barometric pressures and diagnostic updates. It also includes all previous calibration updates/fixes. Broadcast Message 0763/SSM 17048

The scan tool update implemented on 8-22-03 will cause a fatal exception error in the scan tool if model year 2004 is selected. Until a fix is released, select 2003 for 2004 models. Currently the calibrations are identical. Broadcast message 0798.

TorqShift Transmission Firm Tip-In and Tip-Out While in Tow/Haul:

Some customers may complain of bucking or jerking when firmly depressing the accelerator while in Tow/Haul mode. These torque ocsillations should only occur in Tow/Haul because the torque converter is programmed to stay locked to provide engine braking in that mode. Engineering is investigating ways to improve this symptom. If this problem occurs out of Tow/Haul, normal diagnosis should be followed to find the cause. Broadcast Message 0695.

6.0 Turbo Lag Following Cold Soak:

In some cases after the 6.0 is allowed to fully cool in temperatures between 30-60 degrees, it may exhibit increased turbo lag for the first 3-5 accelerations or until the engine warms up. Engineering is investigating this concern. Broadcast Message 0600

6.0 Excursion No Crank After PCM Reprogram:

If this occurs, enter Body/Security/PATS and perform a PATS parameter reset. Do not perform a key code erase. If errors were encountered and no PCM communication results, the original PCM programming an be reloaded using Programmable Module Installation/PCM, providing the session was saved or the WDS was not removed for the vehicle. Broadcast Message 0509/0834.

2003 6.0 PCM/FICM/TCM Reprogramming Errors:

If this occurs, place the session in "complete" status, do not "delete". Connect a battery charger to the vehicle and the A204 cable to WDS. If WDS locks up/does not communicate, reboot WDS by pressing the white and red buttons simultaniously, the the green to restart WDS. Go to previous session and open the original session. Under Toolbox, select Module Programming/Programable Module Intstallation for the PCM only to reload the calibration. Always ensure the WDS has the latest version (check Power Stroke Central on PTS) and both the vehicle battery and WDS are fully charged. Broadcast Message 0525.

2003-2004 6.0 Water In Fuel Lamp Illuminated:

Some trucks may exhibit a water in fuel lamp that continues to illuminate after draining the water separator. This may be due to sedimate build up in the water reservoir. Check the electrical connections at the fuel pump assembly. Replace the fuel manifold with part # 3C3Z-9B249-AB. TSB# 04-9-2 .

99-03 Super Duty F-Series Two-Piece Driveshaft Shudder:

Some trucks may exhibit a vibration on moderate to heavy acceleration from a stop. This is usually due to too high of an angle through the center u-joint. The correct angle through the u-joint should be 0.5-3.0 degrees (compare front shaft angle to rear shaft). Check the engineering number of the center bearing bracket to ensure it is the correct application, and replace if necessary. If the bracket is correct, the shudder may be corrected by shimming the bearing down from the bracket using up to three 1/4" shims, part number E0TZ-4A209-A and two grade eight bolts long enough to expose three threads above the nut when tightened to 46 ft/lbs. Loctite is recommended. Broadcast Message 0518, 1475.

6.0 Rolling/Rough Idle (surge/lope) After Hot Restart:

Engineering is investigating a concern of an erratic idle after a hot restart. The condition may clear up on throttle tip-in. Currently there is no fix for this condition. If a truck exhibits these symtoms, unplug the engine oil temp sensor to see if the idle stabilizes. If it does, do not attempt a repair. Disconnecting the EOT sensor eliminates the initial injector actuation of the split shot sequence. Engineering has found that the cause of the rough idle is a problem in the programming for the initial injection.

Broadcast Message 0425

6.0 Enhanced PCM Calibrations:

Some 6.0 F-Series and Excursions may exhibit a low power, low boost condition which clears when cycling the key off and restarting. This may occur while driving or after start-up. Other symptoms may include false cooling fan code P0528, and/or no or slow throttle response when engaging the TorqShift automatic transmission in gear. These symptoms may or may not become apparant after having the recall 03B06 performed prior to the end of May. The enhanced calibrations are available only with WDS versions 24.11 or later. Trucks that have had 03B06 done will only have PCM and TCM updates. Those which have not had the recall done will get PCM, FICM and TCM updates.

Broadcast Message 0356/SSM #16839.

Fuel Level Less Than Indicated by Fuel Gauge:

Some F-Series and Excursions built between 12-1-02 and 4-14-03 may exhibit an inaccurate fuel level reading after refueling. In most ases this is caused by refueling with the ignition in the on or accessory position. The fuel gauge should eventually reinitialize on its own, but it can also be reinitialized by disconnecting the batteries. If the gauge dose not reinitialize, then the fuel level system should be diagnosed.

Broadcast Message 0926

6.0 Air Cleaner Housing Appears Warped/Misaligned:

The appearance of a misaligned sealing surface between the air cleaner and mass air flow sensor is due to the design of the air induction system and the positioning of the clamps. The air cleaner should be sealed providing the gap is not greater than 16mm (5/8"). If the gap is greater than these measurments, attempt to reseat the air cleaner to the mass air flow sensor. If the gap is still too wide, replace the air filter element only.

Broadcast Message 0925, 1581

Variable Geometry Turbo Solenoid Diagnosis:

Some trucks with the 6.0 diesel engine may exhibit a lack of power/no boost concern. The variable geometry turbo (VGT) actuator should be checked for operation: The engine should be at operating temperature. With the engine running and the engine in park/neutral, use WDS to control engine speed to 1200 RPM. While watching exhaust backpressure (EBP) and manifold gauge pressure (MGP), control the VGT actuator (VGT_DC) to 0% and 65%. If the MPG and EBP do not increase as VGT_DC is increased, inspect the wiring to the VGT. If there is no problems found in the wiring, replace the VGT actuator (P/N 3C3Z-6F089-AA) and retest. If there is no change, replace the turbo. SSM 0824.

If the EBP does increase, and you can hear the turbo pitch change, but the MGP reading does not change, this indicates a problem other than the VGT or turbo.

2003 6.0 Driveability/TorqShift Shift or Engagement Concerns:

This is now covered by Customer Satisfaction Program 03B06. It applies to trucks build through 2-23-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.

Some trucks may exhibit a rough surging idle in drive or reverse when cold , poor throttle response when cold, or low power after extended idling cold. Other symptoms may include harsh shift engagements, harsh 2-3 upshift, 5-3 downshifts and cold 3-5 shift flair. There is a revised calibration for the PCM, FICM and TCM--all must be reprogrammed as a set using WDS version 24.6 or higher.

ICP Sensor Problems:

This is now covered by Customer Satisfaction Program 03B05. It applies to trucks build through 2-3-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.

Some 6.0 PowerStroke engines may exhibit rough/rolling idle, poor idle return, lack of power, injector fault codes or excessive smoke. This may be caused by the ICP sensor reading incorrectly. The ICP sensor and connector terminals should be inspected for damage (the ICP is at the rear of the engine, under the turbo), and the sensor circuits checked for opens or shorts. With the engine at operating temperature (engne oil above 180 degrees), the ICP sensor signal should be 0.16-0.28 volts (less than 70 PSI) with the key on and engine off. The engine needs to be off for at least two minutes for this test. If the ICP signal is not within this range, replace the sensor with P/N 3C3Z-9F838-EA.

Runs Rough, Lack of Power, Oil Level Overfull/Fuel in Oil:

This may be due to fuel leaking through or around one or more fuel injectors. There is a comprehensive TSB that has step-by-step diagnostic procedures to isolate the problem to determine in which bank the leak is occuring and to identify which injector and whether it is an o-ring or an injector failure. Note: If more than four quarts of fuel is present in the oil, the turbo charger shaft end play must be inspected. If end play is greater than 0.004", or if the compressor fins have come into contact with the housing, the turbo must be replaced. After replacing any leaking injectors, the oil and filter should be replaced and the truck driven 20 miles. These steps need to be done twice more before releasing the vehicle.

TSB #04-9-3.

Diagnostic Communication Error:

A failed PCM message may occur when diagnosing 6.0 PowerStroke engines. Insure the WDS software level is B23.0.7 or higher. Wait at least four seconds after turning on the ignition before initiating any tests. If the message re-occurs when repeating the test, check the ground at the DLC, perform PPT "AE", and check voltage at the DLC pins 6 and 14 with the key on/engine off--it should be 2.5 volts +/- 0.5 volt.

Rough/Surging Idle, Excessive Smoke, Lacks Power, Poor Throttle Response:

This may be accompanied by DTC P2263. Inspect all intercooler hoses and pipes and exhaust system before the turbo for leaks. Ensure the oil level is correct there are no oil leaks and all electrical connectors are secure. Check the ICP sensor as in the following bulletin. If no problems are found, make no attemp to repair the condition. Engineering is investigating. Broadcast Message 0225, 0471. SSM 16488.

Diesel Engine Power Module-Fuel Injector Control Module Monitor Circuit Shorted:

Some trucks may have DEPM DTC P0148 (fuel error/engine speed higher than expected) and/or P2552 in the event the FICMM is shorted or open. DTC P2614 (cam position sensor failure) and P2617 (crank position sensor) may also be set. If these sensor codes are set with the P0148, do not attempt to diagnose the CMP or CKP sensor circuits. Broadcast Message 0059.

PCM Update:

Some 6.0 PowerStroke engines may exhibit a surge or unstable idle after cold start-up. There is a computer update program for this concern, as well as enhancements to the Cold Ambient Protection (cold high idle) strategy. Affected calibrations are HBF7, JEL7, MAT7, BKG7, FFM7, KMA7, NFW7 and PBD7. Broadcast Message 0417.

TorqShift 3-4 Shift Flair:

Some trucks built before 12-16-02 may exhibit a shift flair when upshifting from third gear. There is a computer update for this concern. Affected calibrations are BKG6, FFM6, KMA6, NFW6, and PBD6. Broadcast Message 0232.

Lack of Power, Hard/No-Start, Runs Rough on Delivery:

Air in the HP oil and fuel systems may cause the above symptoms. The vehicle should be driven 30 miles to purge the air from the passages. If this does not resolve the concern, use WDS to command the variable geometry turbo actuator to cycle. If the concern is still present, continue diagnosis. Broadcast Message 0211.

TorqShift Transmission--Incorrect Dipstick:

If the transmission fluid appears to be low on a TorqShift transmission, the dipstick may be wrong. The correct part number is 3C3Z-7A020-BB. If the fluid is in fact low, the correct fluid to use is Mercon SP. Broadcast Message 0397.

Lacks or Loses Power in Cold Temperatures:

This may be due to fuel gelling or moisture freezing and reducing fuel flow. It is recommended to use a fuel conditioner, such as Stanadyne Performance Formula, to prevent this condition. Do not use conditioners that contain alcohol. Broadcast Message 0436.

Fuel Rail Plug Leak:

Some engines may have a fuel leak at the rear of the cylinder head(s). This may be due to a misaligned fuel passage plug seal. Replace the plug and seal with P/N 3C3Z-9K042-AA. Broadcast Message 0523, SSM #16634.

No Crank/No Start; Vehicles with TorqShift Transmission:

If this condition is occurs it may be due to a problem in the cooling fan electric clutch. This may be accompanied by transmission range sensor codes P1705 (TR not indicating neutral on self test), P0706 (TR-P sensor frequency fault) and P0707 (TR-P sensor circuit duty cycle low input). Check the voltage at the TR sensor pin 21, circuit 371, it soould read 12 volts. If the voltage is low (3-4 volts), unplug the cooling fan electrical connector and retest. If the voltage is now 12 volts, try starting the engine. If it starts, clear codes and test drive to see if the TR sensor codes return. If they do not, diagnose the cooling fan electric clutch. Broadcast Messages 0520, 1069.

Loose Radiator Hose Clamp:

A coolant leak at the radiator hose may indicate a broken or weak hose clamp. If a leak is present, allow the engine to cool down. Check to make sure the hose is fully seated on the hose fitting. Install service hose clamp 3C3Z-8287-EA up against the exsisting clamp (no need to remove hose) and torque to 31 in/lbs. Warm up the engine and check for leaks. Broadcast Message 0495.

The hose clamps can also be replaced by using a heat gun to soften the glue retaining the clamp to the hose. Remove the clamp and replace with P/N W710044-S900 for 2" hose ID or W710043-S900 for 1.75" hose ID. Broadcast Message 0529.

6.0 PowerStroke Calibration Update History
6.0 PowerStroke Calibration Update History

2003-2004, up to 9-30-03

Running Change 1, available 12-16-02

Addresses:

3-4 Shift flair

Running Change 2, available 2-4-03

Addresses:

Rough idle in park/neutral on cold start/restart

Cold idle kicker enhancement

Running Change 3, available 2-24-03

Addresses:

Rough idle in drive/reveres on cold starts

Poor throttle response on cold starts

Low power on cold start or after extended idling (may clear by cycling key)

Harsh TorqShift engagement/2-3 upshift

TorqShift 5-3 coasting downshift

Cold 3-5 shift flair

Modified TorqShift shift position sensor values

Activated cooling fan trouble code P0528

Running Change 3s, available 4-3-03--FICM only

Addresses:

Hessitation on light accel

PTO enhancement

Running Change 4, available 5-19-03

Addresses:

Low power on cold start/extended idling (may clear by cycling the key)

False cooling fan code P0528

No/slow throttle response on TorqShift engagement

Running Change 5, available 8-18-03

Addresses:

Rough idle/surge/smoke on light throttle tip-in

Improved A/C performance at idle

Minor manual transmission launch performance enhancements

Smoother tow/haul downshift at 20 MPH

Improved low altitude/high barometric pressure performance

Diagnostic and network communication upgrades

Running Change 6, available 10-3-03

Addresses:

Improved performance on hard accel after cold start

Loping on hot restarts

Cold idle kicker enhancements

False PCM/FICM program incompatibiliy code U0306 after reprogramming

Turbo system performance code P2263 enhancements

Engine oil temp sensor performance code P0196 enhancements

Running Change 8 (orig. RC7), available 12-12-03

Addresses:

Improved hard acceleration performance at high altitudes after cold start

Rough running/misfire at high altitude after extended idle on cold starts

Check engine light activation for turbo performance code P2263 turned off (49 State emissions only)

Harsh 3-2 coasting downshifts or clunk/buck/jerk on accelerator tip-in/tip-out in tow/haul

2004.25, after 9-30-03

Running Change 1, available 1-30-04

Addresses:

Improved cold start and hard accel performance at high altitudes

Rough running and/or misfire after extended idle on cold starts at high altitudes

Rough or rolling idle immediately after cold start

Check engine light activation for turbo performance code P2263 turned off (49 State emissions only)

Harsh 3-2 coasting downshifts or clunk/buck/jerk on accelerator tip-in/tip-out in tow/haul

P0299 turbo under boost enhancements

P0500 vehicles speed input enhancement for manual transmission

TorqShift harsh reverse engagement on low mileage vehicles

Econoline RC1, available 2-26-04

Addresses:

Engine sped under run on long decel in manual second or third gear

mroved fuel pump diagnostic code P0231

Souces:

Dieselmann

TheDieselStop