Hello all,
Thanks so much for the help and Ideas on what might have been causing the surge on my 6.0. Well I have found the best dealer to take it too, they found the problem called ford "they are aware" of this problem over nighted the part and I was back on the road.
If you have a bad ford dealer in your town, Try the lincoln dealer, I did they have a diesel tech and honor the factory ford warranty.
anyways, It was a bad VGT sillanoid, some how it controls the speed of the turbo, mine was bad and would constantly open and close causing the surge problem.
I hope this helps out someone else
MRCONCDID

 

how bad was your surge? I have an occasional surge but only when im at a stop light i can see the tach "bump up " about 100-200 rpms for a split second, it does it about 20 times a minute when it happens i cnat seem to point a finger at anything in particular that makes it happen? So im not gonna bring it in until i need to, truck has been prettymuch perfect thus far with 28,000 on the ticker and i dont know any reliable techs in my area?

 

I had the same problem with my truck it was like the turbo was cycling and I wasn't moving the throttle. I changed my EGR valve 2 weeks ago I guess I never cleared the KAM right so I was still having some problems. Today I had some free time today so I reset the KAM (keep alive memory). The problem seemed to go away it may come back. I know I need a turbo replacement soon my truck is a 03 with 65,000kms (40,391 miles) on it. Truck has had a reflash in 2005.

 

how much did the VGT seloniod cost you mr concdid??

 

My 04 has been in the local shop for about 2 out of the last 3 weeks for a surge problem. First time I dropped it off (at 95,000 miles) for a severe bucking or surging at idle, they found a bad mass air flow sensor and an EGR Cooler. They also mentioned something about coolant getting on the mass airflow sensor from the overflow bottle, but did nothing about it.

350 miles later, it was back in the shop for the same problem. Now it's sitting there with the cab lifted, waiting on a pair of heads to show up from somewhere, sometime on Tuesday. They're also changing out the oil cooler, but not too sure why. They say the heads were pitted and were allowing oil to get into the coolant.

Now, can anyone tell me just how these two components could have caused my buck/surge/stall problem? My truck is close to 96,700 miles and I really hope this is the last time I'll ever have to take it in for this problem. I've only had this things since the 24th of March and it's been into Ford 4 times. The first time was the day I bought it (w/ 92,500 miles) when the VGT Solenoid went out along with the throttle position sensor. Seems that either my truck knows it's warranty is almost up, or I bought a lemon.

Either way, I'm fixing to sue the owner of the store that I bought it from, but that's for another post, after I've filed and taken his sorry butt to court.

Any thoughts?

 

The VGT solenoid is about $250 or something like that. There is an updated one from the earlier models that is supposed to have a little faster response. One of those things on my "wish" list I can't justify buying right now that I though might help with my turbo surge (I have a modified '03 turbo).

There is/was one of the flashes that cycled the turbo up and down at idle to keep the turbo vanes from sticking. I don't know if it's still in use or not.

 

mine seem's to feel like its building boost on its own(and pull through the brake)...ford wont touch it due to no cat...so i guess i have to replace it my self.

 

The VGT was under warrenty (16,000) miles, Didnt cost me a dime.Dealer told me it was a bad part they have seen a few with problem.Ford knows about and prompty sent the part.
You ask how bad was it? well maintaining speed it would surge up and down while I kept the accelerator steady, If I jumped on it it would surge during the whole acceleration untill I would let off, Last time I was pulling a load 8,000 lbs if buck 3 times while climbing a hill at 65-70mph thats when I took it to the shop, to tell you the truth whren I drove away from the dealer I was alittle scared to get on it. But that only lasted a few miles, I didnt relize how much power I had lost, It really feels lilke a new truck again.
I hope this helps

 

Clear the KAM and perform the VGT relearn strategy! Doing 1/2 the job will net 1/2 the benefits. I'm doing mine this weekend. I installed a new exhaust, but didn't finish the job by doing this part--yet... Ya' all should also be very vigilant about your oil level, quality and viscosity. On my next change, I'm going to use synthetic, not dino. I've noted several oil related issues as the summer gets hotter... I've read good reports about using synth in the summer.
For reference:
KAM (keep-alive-memory) reset & VGT learn procedure <o> </o>

• Drive the truck to bring it completely up to operating temp - VGT learn procedure requires that the oil and coolant temps be high enough to allow EGR operation...
• Disconnect both battery ground cables at the same time... turn the headlights on for about 10 minutes - this will deplete any devices that even have a chance of retaining KAM in the PCM. <o> </o>
• Turn off the headlight switch and reconnect the batteries. <o> </o>
• Cycle the key to the run position twice to allow the clear procedure to complete..... Pause in the on position long enough for the wait to start lamp to prove out and pause in the off position for 10 seconds to be sure the PCM has "gone to sleep". <o> </o>
• Start the truck and leave it idle for at least 5 minutes... you will likely hear the turbo pitch change several times during this period as the PCM learns the necessary duty cycles for accurate VGT control..... <o> </o>
• Now you can road test it and the process should be done...

 

this is good info i will try this tonight to see if it clears my surge. thanks for the god info they should put that in the tech folder if it isnt in there already.

 

It's not... The suggestion has come up several times, but still no tech folder listing. Best of luck! I've had very good results a time or two.

 

My truck has developed a surge/ rough idle that is very intermittent. It only does it once ever week or 2 and last for the night and then goes away. I have tried to be very observant while driving and it doesn't seem to be caused by any specific driving habbits. If anyone can, will you listen to the video and see if it is like what you have experienced and cured? I replaces the exhaust back pressure sensor and don't want to keep throwing money at it guessing. No codes have ever been present, no check engine lights or anything.

https://youtu.be/sH0L5m6pDjE

 

8 year old thread.

Have anything to read live data? Watching the VGT% as command may be a better way to diagnose the issue.

 

OhI didn't realize that. I started a new thread also, but just was curious what others experienced. I just have the sct programmer and it doesn't have that function.

 

I just wanted to drop a comment saying that I was having a major surge while stopped at a stoplight, so bad that I would put it in neutral and then it would sometimes stall. I could feel the surge at constant pedal. Thing was the problem was only after it got to temp. Long story short and $4000 later it was the icp pigtail. It wasn't shorting but the old wires were getting to hot. Crimped a new one on after burning myself with the soldering iron and problem completely solved. The pigtail didn't have any oil in it and looked fine. It was the factory pigtail I believe. So take the $20 and replace it if you're having surging issues, it may solve your problems.