06 Powerstroke starts without issue, but the engine sounds very noisy (unusual rattle). Take it onto the street and she doesn't want to go. Once she gets into 3rd gear, the engine settles down and she's fine all day. This problem has only started since the cold weather came in. When I say cold, I mean California cold ... high 30s to low 40s.

The truck has 114K and has had regular oil changes at 3K. Motorcraft filters and oil (except for last oil change, used Rotella dyno).

 

I mention this because i just repaired a truck with a similar symptom. after verifying the oil system and ficm operation and found no issue we looked at fuel pressure. We found a damaged regulator. From my experience the lower the fuel pressure the louder the injection system is. It may be your issue it may not be but its worth a mention. Have you had a scan tool on the truck yet? Your issue really sounds like a ficm problem have you seen the sticky on the ficm testing?

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Have batteries load tested first, then check your FICM. FICM test procedure at the top of the 6.0 page. Report back here and let us know what you find. Between batteries and FICM, they're probably 90% of the cause of these issues. If those check out we can go from there.

Sounds like a good time for the Ford blue FPR spring upgrade.

 

Thats what it got. Someone had stripped one of the regulator bolts but otherwise i couldn't find anything wrong . Spring and seat were correct. Blue spring mod and pressure hit 65 instantly.

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The springs kind of lose life after so many miles and just can't hold the pressure they used to. Couple that with the newer ford fuel filters with the redesigned lower filter (big o-ring sealing it now) which IMO is why Ford brought the blue springs out in the first place... easy to see why some run low on fuel pressure and owners never know. Fuel pressure gauge is so important in these trucks. Right up there with coolant filter IMO.

 

Update: I just got a call from the wife (she's driving the truck this morning) ... it threw a CEL ... so I'll be hooking it up to the scanner this evening. She said it is running fine; not rough at all.

As far as batteries are concerned, I just replaced both of them a couple of months ago with OEM Motorcraft batteries. She's been starting better than she's ever done. I'll report more after I pull the codes.

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Looks like bad injectors. P0267-#3 injector and P0279-#7 injector. Thank God for extended warranties! I've got an appointment tomorrow afternoon to drop her off at the local Ford dealership.

 

Try that route first, with the dealer. If they dick you around, throw in a couple bottles of rev-x oil additive.

 

I used the warranty once before, for a rear main seal, and didn't have any problems having it covered, so I'm hoping the same will happen here.

A couple of questions for you:

I've been changing my oil (Motorcraft 15W40) every 3000-3500 miles; is this a bit of overkill? I was considering an FS-2500, before extending the oil changes to 5000 miles. What do you think?

Do you think that Rev-X would correct an injector problem like this?

Have you looked at the Archoil AR9100 additive for our trucks? It is a LOT cheaper than Rev-X and appears to do a better job. There are a couple of videos on YouTube showing its use after Rev-X did not work. This stuff is pretty amazing!

I know Ford recommend the fuel filters changed at 25K; is that sufficient? I have about 15k on mine at the moment.

I'm considering having a trans flush done, while she's in for the injector problem. The truck has had its tranny flushed every 25K up to 75k. I've got 114K on it right now, which puts it at 39k since the last flush. Do you think a full flush would hurt at this point?

Thanks for the input so far!

 

I did a oil flush and put some rev-x in the truck i mentioned above. I could literally could see the misfire counters decrease from around 150 to around 15 and finally to 0 in 7 minutes.

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None of the oil additives will ever "cure" this problem, but they will mask the hell out of it. The issue is once you drain the oil, the additive is gone and the problem is back... so yes it will likely make most of it go away, but you have to keep adding it. My advice, leave it as is and try to get it fixed under warranty first. Injectors are tough since they seem to work like crap when the engine is cold and get better as it warms up, so it's sometimes hard for the tech's to catch it.

I'd go 5k on the oil changes without worry and without the FS2500.

I have looked at the archoil, and will likely use it this next go around. I still tell people to use rev-x, because I have personally used it a bunch of times and know it works. I would just hate to tell someone to use the archoil without having tested it for myself you know?

Doesn't seem like it would hurt to do the trans flush.