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Old 06-15-2014, 10:20 AM   #1
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Has anyone had multiple cam sensor failures on the 6.0 PSD

I have had 4 or 5 cam sensor failures on the 6.0 PSD, dead in a parking lot right now.

Any idea why the multiple failures? My mechanic is at a loss.
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Old 06-15-2014, 11:35 AM   #2
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

Are you sure it is the sensor itself?
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Old 06-15-2014, 11:56 AM   #3
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I'm kinda with Dave. I'd be suspicious of another root cause. Maybe a loose wire (usually at the connectors) is making contact again after being moved to change the sensor. It is one part that is not typically a problem on the 6.0.
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Old 06-15-2014, 03:58 PM   #4
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I had one cam sensor failure at just over 100K. After replacing the sensor, the tech said "Cross your fingers and hope it wasn't a wiring issue."

First, this time how do you know it is another cam sensor? Must be 20 other things that can cause a no start, including a more common EGR valve.

I'd try wiggling the cam sensor wires, simulating changing the sensor and see if it starts.

Mike
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Old 06-15-2014, 06:08 PM   #5
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

Well every time after the first ( when he changed both the can and crank sensors) the cam sensor change fixes it. He gets a cam sensor code. It started a bit later today, which it used to do. Most of the last few times it would not so I'd have it towed. Of course I need it tomorrow since I'm 7 hours from home with a cargo trailer. Mike had checked the wiring, the pins.......
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Old 06-18-2014, 09:31 PM   #6
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I would suggest you get an Autoenginuity kit and start monitoring it and a few other parameters at the same time.
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Old 07-29-2014, 04:28 PM   #7
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I'm a bit late on the reply, but it's more than lightly a wiring harness problem. My 6.0 had a very similar problem, would not start and after 10 or so failed starts would finally throw a cam censor error code or cam / crank out of sync error code. It would only ever do this randomly so was a real pain to diagnose. After a period of time I found that I could reach down to the wiring harness that runs under the coolant reservoir to the FICM give it a tug, and all would be fine for the next 2~5k miles or so.

The FICM wiring harness is not all that expensive, but replacing it is a nightmare. So I decided to pull it apart in-place and see if I could track down the issue.
There is a ton of information on this issue on the 6.0 PSD trucks, and a lot of it is the same for the van. My problem / chafing location was described in a Ford TSB. (First image of page 5 in the below link)
http://www.thedieselgarage.com/forum...6&d=1201892575

I couldn't find a neat way to stop the harness rubbing on the manifold bolt. I first thought about making a semicircle bracket that bolts to the manifold and acts as a cradle for the harness, but ruled that out as I could only make one from metal and I was worried about heat buildup. So in the end I zip tied it (with quality ties that will stand up to heat), to the engine lift bracket you see in the picture. Not shown in that picture is the second fuel pump location on the E350, I also put a rubber sleeve about one of the metal fuel pipes and zip tied it to that. Both of those locations raised it 1/4 inch off the offending manifold bold.

This URL is also a must read to diagnose the issue.
http://www.powerstroke.org/forum/6-0l-p ... -here.html

I had stripped all the harness sleeving material back from the FICM to this point to find the issue, it's about as far back as you can go without pulling the harness from the vehicle. But if I was doing it again, I'd go right to that spot and start looking at it carefully. You will need to remove a bunch of stuff to get their though.
Move Coolant reservoir out of the way.
Put firewall harness out of way (same procedure for upper/small filter change).
Move power steering reservoir
Pull intake tube (the one that runs from air box to intake).
Pull turbo piping (right side of radiator, and upper one).
Probably a few other small items.
Then you can unplug harness from FICM, then ECU, and few other spots, you should be able to untangle it from all the other items without removing them.

All that will give you JUST enough room to work on that spot.
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Old 07-29-2014, 06:02 PM   #8
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I had a second failure to start due to the cam sensor. This time the tech isolated it to the wiring. Ford actuallymhas a pigtail to replace the connector and associated wiring. It is possible that my first cam sensor failure was the same wiring issue, but moving the wires to replace the sensor may have reset the break. Funny thing, it was fine over thousands of miles of bad road and failed in a smooth parking lot in town.

Mike
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Old 07-30-2014, 08:06 AM   #9
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

Quote:
Originally Posted by Ford_6L_E350
Ford actually has a pigtail to replace the connector and associated wiring.
Do you have any more information on this, link, part#, pic etc etc?

Quote:
Originally Posted by Ford_6L_E350
Funny thing, it was fine over thousands of miles of bad road and failed in a smooth parking lot in town.
Lucky mine would usually fail in the driveway after it had been sitting for a while. The few times it failed when I was out I had already worked out what wiring harness to tug-on to get it to start again.
Mine never failed once started though, ie it would never stop the engine once running, only caused it to fail to start.
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Old 07-30-2014, 11:00 AM   #10
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Re: Has anyone had multiple cam sensor failures on the 6.0 P

I don't know if it is lucky to fail in a Loews parking lot or not. Had to wait 2 hours for the tow and about 3 hours for testing/repair.

The pigtail is #WPT-359. At least, that is what I was billed for. I see many sources online, but I'm not sure if it is the correct connector or not.

Mike
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