Weird problem on 95 PSD

[RocKrawler]

New to the diesel thing so bear with me... bought truck with following setup:
1995 CCLB Dually, orig owner, meticulously maintained, 110K orig miles
Full Banks setup including intercooler, turbo housing, git chip, & K&N open filter
4" exhaust
Banks Brake
Stock 4.10 gears & LSD

What happened:
Driving home & doing 65 on open road, truck coughs and seems like it completely lost power for about 3-4 seconds, then resumes as normal but check engine light comes on, stays on until I get home but truck drives normal the rest of the way. Next day truck starts and drives perfectly.

Then 3 weeks later:
Driving home on freeway about 65-70mph, same cough, doesnt lose power when it recovers until I exit at an offramp. When I come to a stop the check engine light pops on, and truck has zero power off the line & is smoking on accelleration (nighttime, couldnt tell what color) for about 10-15 seconds. At about 1500 RPM the turbo spools hard, boost between 10-15lbs but power not the same & wierd whoosh sound when you let out. On dark empty road so I keep going to try & get somewhere I can check it out in a parking lot with light. Same thing for the next few lights, dead off the line, then tons of boost, low power, and 6K-8K exhaust temps, check engine light still on, but not smoking anymore. Stopped at the lights the idle is bouncing between 500-800 rpm but never stalls. I pull into a parking lot finally and shut off engine, pop the hood, everything looks normal. Oil level fine, nothing making baked crackling sounds, no leaks or holes in anything. I close the hood, get back in, start it up and its like nothing ever happened. No check engine light, no fluctuating idle, no power loss off idle, no crazy boost with no power associated, nothing.

Its now 5 days later and it acts like nothing ever happened other than the temp gauge seems to have an intermittent connection now and bounces between cold and normal running temp(1/4 to 1/3 up off cold) Any idea what could cause this? It seems shutting off the motor resets the problem, and it warns you with a hard cough if the check engine light is about to come on and thngs are going to get funky. HELP!

 

[94f450sd]

first thing you need to do is have a scanner put on it to get the codes from the check engine light(CEL).

it could be the CPS,exhaust back pressure valve(EBPV)closeing,and intercooler boot leaking.

 

[clem]

I agree with Rich, the CPS is shot.

 

[RocKrawler]

I'm searching and finding multiple part numbers for both Ford and International units, which one to buy and cheapest place to buy it?

 

[threejacks]

Try this SDD sponsor $82.66 for 95 model. Scrool down this page:

http://www.trademotion.com/partlocator/index.cfm?siteid=214083

Sometimes it can be found on eBay for 50-60 dollars, but none today.

Dealer will ask 175.00-200.00 for one.

 

[johndeerebones]

Ipr

Not discounting these guys one bit but there are couple things I would check that you can do for free.
By all means get those codes read if you can do it for free somewhere.

I would check the wires to the ipr. The insulation on these wires gets all gooey from fuel and the short against each other causing exactly your systems untill they short together and stay together, then you're dead in the water. I have had this problem for about 3 years, just keep patching it to make it work. The plug is the same as the injector plugs or you can just buy the whole new fuel bowl harness to get it for 65.00 from Ford last time I checked. I have long skinny fingers, so I can jiggle the wires without taking anything loose, but if you pull the fuel filter bowl and harness you can get right at the wires and connector body.

I would also pull the fuel filter and look at the heater element in the bottom of the canister, the solder spots on it can break loose and the element shorts around and causes odd problems, but this one usually blows a fuse, as it makes a dead short and a high amp draw. If the fuse blows you will have a no start, so yours isn't blown yet.

A cps is a definate possibility, but the usually stop ya cold, and may or may not restart. Good luck, keep us posted. I hate intermittent problems can be such a pain, just don't end up spending all kinds of jack to still have the same problem. Get the codes read.

On edit, also might pull clean and check you chip connection too, or even run without it for a bit.

 

[JOAT]

...snip...
I would also pull the fuel filter and look at the heater element in the bottom of the canister, the solder spots on it can break loose and the element shorts around and causes odd problems, but this one usually blows a fuse, as it makes a dead short and a high amp draw. If the fuse blows you will have a no start, so yours isn't blown yet.
...snip...

Just wanted to add to that. The Fuel heater normally won't short in the summer, because theres a 32*F snap thermostat where it connects to the bowl. Still good to check that thing to be sure. Also the wiring to it outside the bowl sometimes shorts, as diesel breaks down the insulation.

 

[RocKrawler]

Try this SDD sponsor $82.66 for 95 model. Scrool down this page:

http://www.trademotion.com/partlocator/index.cfm?siteid=214083

Sometimes it can be found on eBay for 50-60 dollars, but none today.

Dealer will ask 175.00-200.00 for one.

$93.16 delivered to my door, ordered tonight. I figure this is apparently a common failure part and will replace it regardless, keep the old as a spare in case that doesnt solve it for long family vacations "just in case". Since turning off the motor seems to reset the issue and clear the CEL I'll wait to see if it happens again (Both times it has have been after 10pm so the Autozone rental is kinda tuff when they are all closed and dont want to leave the truck running overnight). I'll keep the thread updated.

Off Topic: Anyone interested in a new condition 5th wheel tailgate? Its the cleaner louvered stule, not the cheapie square tube style. Make offers!

 

[RocKrawler]

Figured I'd post a shot of my new baby since I'm on...

 

[rtxcoon]

$93.16 delivered to my door, ordered tonight. I figure this is apparently a common failure part and will replace it regardless, keep the old as a spare in case that doesnt solve it for long family vacations "just in case". Since turning off the motor seems to reset the issue and clear the CEL I'll wait to see if it happens again (Both times it has have been after 10pm so the Autozone rental is kinda tuff when they are all closed and dont want to leave the truck running overnight). I'll keep the thread updated.

Off Topic: Anyone interested in a new condition 5th wheel tailgate? Its the cleaner louvered stule, not the cheapie square tube style. Make offers!

the autozone crap wont read your codes....

even if the cel goes out when you restart, the code will store, assuming there is a code set..
you need some software like autoenginuity, or alex peppers OBDII, or dealer, there may be more out there....


if its not the CPS, I agree with the IPR wire suggestion...mine got toasted
(see webshots in my sig under DA TRUCK, then diagnostics) the wires degrade with time/diesel soaks/rats...etc...

on 2nd edit , make sure the nut on the IPR (brass thingy on end) is tight