should the fuel pressure drop off like that after pump shuts off?

 

Yes, there is nothing to hold pressure there, despite there being "check valves" in the front of the head, they do a terrible job of holding pressure. It's normal though.

 

Used a 40 amp charger and some ether.
got it running and warmed up today.
Did KOER FICM test - 48 V
Did KOEO and KOER tests with OBD2 reader.
KOEO test - P0261 P0270 P0276 P0279 P0671
KOER test - P0261 P0270 P0276 P0279
P0565 P0566 P0567 P0568
P0569 P1464 P1536

It runs rough and has no power, but exhaust was clean and hot.
Took it to local dealer for a proper scan.
I don't have a Ford scan tool.

 

Sounds like a dead or dying FICM to me.

These codes give it away:
P0261: cylinder 1 fault
P0270: cylinder 4 fault
Po276: cylinder 6 fault
P0279: cylinder 7 fault

Look at page 1 here: http://www.fordtechservice.dealercon...FICM_Guide.pdf

Those 4 injectors are fed off of one plug on the FICM. This would easily cause your poor running condition. Where are you located?

First I would take the batteries out and have them load tested individually somewhere. If one is bad, replace both. Next, do the FICM test procedure, found at the top of the 6.0 page.

Now, the rest of your codes...

P0671 is glow plug 1 issue. Easy fix. You can test the glow plugs as well. I will post that up in a little while here, but I wouldn't even worry about that right now.

All of the P05xx codes are saying issue with cruise control... and the P1464 is an issue with the cluster communicating with the PCM. Was any of the cluster moved or touched recently? P1536 is a parking brake circuit error, which may tie into these other codes as well.

 

Thanks for the FICM guide. That makes some sense of why all 4 injectors are showing circuit low. Over on page 3 it says, On 2004.25+ (1845117C2 FICMs), the low side driver is actually shared among 4 injectors. This means an injector short to ground on the low side could produce four different cylinder error codes.

Not sure what injector short to ground means. Could be one of those chafing wire issues.
Something to do with connector C1388A (X1). And of course it could be the X1 low side driver bank in the FICM gave out.

I did the FICM 48 V test KOEO Init, KOEO postinit, starting and KOER, and they were all 48 V +-0.4V - within spec.

Will definitely look into the batteries but they are less than a year old. Not too worried about the other codes yet.

 

If the batteries are good and the FICM tests out... go over that wiring harness with a fine tooth comb. The guide will show you which wire you're supposed to be looking at. Another thing is to pull the FICM up and make sure those plugs are pushed in TIGHT. They can be a pain to get in, but ensure they're in there good.

 

The Ford mechanic hooked up the IDS and did individual buzz tests and CC tests.
He said the buzz test passes - all injectors sound strong when buzzing. The problem is in the injector low side driver of the FICM on the X1 bus. Don't know which one, not that it matters. FICM is dead even though it passes the high side driver (48 V) test. He said he wiggled the X1 and X2 harnesses and it didn't remove the fault. I decided to let them install a remanufactured FICM and flash the injector driver strategy onto the ROM. I just don't know enough about that half shell operation to attempt a power inverter replacement at this time.

 

Yikes, bet that cost a pretty penny. You can order just the half shell from Ford, all you do is unbolt the old one and slap the new one on... anyone can do it.

Only a new FICM requires programming. I bet it could have been fixed.

Do you still have the old one? Or did they take it for a "core."?

 

They said they don't have the half shells, or don't do that kind of operation.
The bill will be around $1250.
Not quite what i need right here before Christmas.

They keep old FICM for core ($175).
Besides they will have to flash the latest calibration onto the new(reman.) FICM.
I have doubts as to whether it might still be the X1 harness or something else.

Before 2 weekends ago, i had ever only popped the hood to gawk at the beast.
Maybe with the excellent help and guidance you have given, i'll be ready for the next failure.

So different from the gassers i have worked on; Dual oil pumps, direct injectors, oil rails, turbocharger, HFCM, 4WD.....
All said, i am a devoted Powerstroker. Love that stinky beast!!

 

Ouch... most places only charge $200-$300 for a full FICM repair... warranty included, and no need to reprogram.

Saying they don't have the 1/2 shells is complete BS. I've never seen a Ford shop that can't get them, and it's literally unbolt the old part and bolt the new one back up, it doesn't get much easier.

If you've already gone through with it, so be it, but if you haven't I'd put a stop to that ASAP.

Heck, you could just go buy another FICM for less than that through Innovative, Swamps, etc... even bulletproof diesel has a new over-built adjustable voltage FICM for less than that...