Ok so I don't see any mention about the fuel filter. Has it been replaced? Have you been able to drive it with a fuel pressure tester hooked up to see what the pressure does when the problem happens? Have you pulled the settement bowl (switch valve see pic included) to make sure there is no filter in it (have found there to be on in it from time to time).?

Answered by racefan966 (expert)
4,866 answers provided

Fuel filter is new. I have not checked pressure while driving, my tester is nowhere near long enough. At idle (and revving it up sitting still) the fuel pressure is correct. And I have not pulled the bowl on the switch valve, but I will try that as soon as I get a chance. Don't know if it makes a difference, but the fuel tanks were spotless on the inside, no dirt/corrosion.

Response from speedylube
2 questions asked

No that dont matter much, its good the tanks are clean. Now just be carefull not to mess up the oring that seals the bowl. I have now had 2 trucks (one of my own and one a customers) that have had filters in the bowl and there should not be. Now as for the fuel pressure test while running is there anyway you can put the guage under the wiper and shut the hood so you can drive it and see what the fuel pressure does when it acts up? Does the check engine light come on? If so have you been able to get codes?

Answered by racefan966 (expert)
4,866 answers provided

My gauge is not gonna reach. I do not see that switch valve/settlement bowl anywhere on the frame. I didn't mention this earlier, but this is an old phone company truck with a work body and a big hydraulic boom on it. It also has a gasoline generator on it. I noticed that the fuel line for the generator has been tee'd off of the return line for the front fuel pump. I don't think that would be a problem though, as the truck's been that way since it was new...

Response from speedylube
2 questions asked

The check engine light has only come on one time (out of about 25 test drives), and even then it recorded no codes and was only on for a very short period of time. The only codes it ever had were some old history codes for the A.I.R. injection solenoids, nothing current.

Response from speedylube
2 questions asked

This truck has a splitter for the pressure line and one for the return, but it has no bowl on it. Any other ideas?

Response from speedylube
2 questions asked

Ok is this actually a super duty?

Answered by racefan966 (expert)
4,866 answers provided

The badge on the side of this truck says "F-Super Duty". I called the local Ford dealer with the V.I.N., they tell me it is an F-450. Remember this is a 1996, so it isn't the truck with the Dodge Ram-style grille (98-present), this one is an old body-style.

Response from speedylube
2 questions asked

I found a re-manufactured PCM for a reasonable price at AutoZone, it will be here today around lunch, I'm going to give it a try...

Response from speedylube
2 questions asked

Ok let me know how it goes. After doing some research with all that you have replaced it makes sense.

Answered by racefan966 (expert)
4,866 answers provided