Stumble, Limp, and 5 trips to dealer

[Highway26]

08 6. 7L 2500 quad cab long box. 26,000 miles.



For the last 18K I've been fighting intermittent issues with 14-15mpg, stumbling and surging at idle, stumbling off the line, low power, and truck going into limp mode (1500 rpm max even in neutral). During the first 10K of mileage I had repeated MIL events.



So far,



They've drilled and tapped exhaust for cleaning

Wrapped exhaust

Replaced ECM

replaced fuel filters

done some EGR black magic

...



We're in the shop again, they can't find any codes, can't reproduce the problem ( I offered to let them go with me this weekend on a trip so they can experience the fun) and now are stumped. They want to rpelace the fuel filter again.



Any thoughts? As for driving habits, not much driving during the week but on weekends it does a 300 mile round trip through the mountains to central oregon with a mix of loaded and empty trips.

 

[MullenaxM]

From your description of the problem this sound like a fueling issue, if the problem only happens after your have driven awhile and the engine is at operating temperature Then you might want to have the check the TIPM (Totally Integrated Power Module, its the fuse box in the engine compartment). The Fuel Transfer Pump in the fuel tank get its voltage from the TIPM. I have seen quite a few of these modules have a intermittent open circuit internally when they heat up.

 

[HBarlow]

08 6. 7L 2500 quad cab long box. 26,000 miles.

For the last 18K I've been fighting intermittent issues with 14-15mpg, stumbling and surging at idle, stumbling off the line, low power, and truck going into limp mode (1500 rpm max even in neutral). During the first 10K of mileage I had repeated MIL events.

So far,

They've drilled and tapped exhaust for cleaning
Wrapped exhaust
Replaced ECM
replaced fuel filters
done some EGR black magic
...

We're in the shop again, they can't find any codes, can't reproduce the problem ( I offered to let them go with me this weekend on a trip so they can experience the fun) and now are stumped. They want to rpelace the fuel filter again.

Any thoughts? As for driving habits, not much driving during the week but on weekends it does a 300 mile round trip through the mountains to central oregon with a mix of loaded and empty trips.

Have you owned and driven previous Dodge-Cummins trucks?

 

[KEpperly]

My truck had a simmilar problem from 700 miles to a little over 4,000 miles, then i took the dpf off and have never had it again. It only did it a total of 6 times it wouldn't rev past 1,500 rpm and could hardly get out of its own way and sounded smething like a 7. 3 ford. I found that when it did it mine would only do it on a warm start up (as in drove some where shut off and go to leave and then it would do it) i just kept shutting it off and turing it back on till it ran normal. I noticed a distinct sound on start up and the motor rolled into life not firing into life like normal.

 

[Highway26]

yup - previous dodge owner and TDR member

Have you owned and driven previous Dodge-Cummins trucks?

Yes - I was on here a few years ago as sardoghauler - had a 01 24v and sold it after about 225K. Why do you ask? Ran like a champ but transmission, front end, and body were betraying me. I miss the rattle but love having brakes. the new truck is a mixed bag.

 

[Highway26]

KEpperly - pardon my ignorance - dpf?

sounds like we may have similar experiences

 

[KEpperly]

diesel particulate filter

I took my truck in a few times for it, but they never had it happen to them. I had a video of how it ran but can't find it, and it did no good at the dealer. It never threw a code and the over head disply said everything was ok. Some dealers aren't to cool about the dpf delete, but the one i go to is ok with it(the only reason i go there).