sudden loss of power, where to start

[fuzzydog]

I have a 95 F250 powerstroke with 5 spd manual. Totally stock

Yesterday after sitting while camping a couple of days, it started up fine like normal and ran fine for about 6 kms of very slow dirt road heading back to the main road. Suddenly I had a major loss of power, engine sounded louder (clackier) and runs very rough. It was a real challenge to get any speed out of it. On some of the major hills on the way home I had to put it in low range. I could build up speed heading down hills but couldn't keep it going up the other side.
It sounds to my untrained ear that I am down a cylinder or two.
Gauges all read good, no check engine light, no leaks.

Got home late last night so no work then but I plan to look at it today. This is my first powerstroke and I got it in May this year and haven't had to dig into it til now. I've done some reading on this site and know to check fuel pressure, injector harness, but do my symptoms suggest anything else?

 

[fuzzydog]

update - took a look in the daytime and the passenger side wiring harness closest to the firewall definitely has some burnt up issues. Is this for the glow plugs or the injectors?

 

[Double-S-Diesel]

glow plugs and injectors both run through the harness

 

[fuzzydog]

I think I have this figured out, sort of.

I popped both valve covers and there is 1 plug on each side that is melted. Each one has an outside wire melted, which is a glow plug. fair enough.

But how does this contribute to rough running. The wires and pins going to the injectors seem to be fine.

Also, why do these connectors melt and what can I do to make sure that the new ones I put in won't do the same thing.

At this point it looks like I am looking at 2 valve cover gaskets, 2 UVC harnesses and 2 pigtails, as well as at least 2 glow plugs (I'll do all of them if they aren't motorcraft - learnt that when I had my IDI). This won't be cheap

 

[Double-S-Diesel]

when they melt, sometimes they short to each other, in turn it grounds the injectors out

 

[fuzzydog]

I found these Dorman valve cover gasket sets online for pretty cheap, and they include 2 pigtails and 2 harnesses for around $60?!?

Anyone have experience with them at all? seems pretty cheap to me

http://www.dormanproducts.com/p-32744-615-202.aspx

 

[Double-S-Diesel]

cheap is what they are , I dont llike them, poor quality compared to OEM.

 

[Kevin 007]

Is this a common issue? How are you guys replacing the wires? Cutting and adding new wire? or is there a kit or harness one has to buy?

 

[fuzzydog]

very common problem from what I have found out. But it is the powerstrokes with electronic injectors that have the issue - not the IDI in your 1990.
Makes me wish I had never sold my 91 IDI

 

[Kevin 007]

I also have a 95 stroke.

 

[fuzzydog]

Sorry my bad, didn't see it in your sig

Ha - I now see that I forgot to change my sig when I got the 95

I got most of my parts today
2 glow plugs, 2 valve cover gaskets and 2 under valve cover wiring harnesses - total damage was about $336 taxes in (Can) from the International Trucks dealer. The VC gaskets were about $30 each cheaper than the Ford dealer, glow plugs a couple bucks cheaper and the harnesses a bit cheaper as well.

I'm having a hard time finding the outside harnesses. Ford is having a hard time finding them and International doesn't carry them at all.

To answer your question, yes, the outside harnesses need to be spliced into the wiring running on the top of the engine.

 

[fuzzydog]

Crazy! The cheapest I found for the outside harnesses is k-mansparts.com at $24 each (and I need 2 of them). Even Rockauto is $49 each. both of those options have shipping, border delays, etc, etc.
For $113 Can I got a complete Dorman valve cover gasket set with 1 vc gasket, 2 inside harnesses and 2 outside harnesses.
I don't like the vc gasket too much - it definitely seems lower quality than the international part I got yesterday but for $113 I got the 2 outside harnesses that I need (quality appears ok) and now I have a 'spare' VC gasket and 2 inner harnesses.

 

[Double-S-Diesel]

Valve Cover Harness Repair Kits (contains 4 hard shells w/seals, w/o terminals)
(Ford) F7TZ-14489-BA (94-96)
(Ford) F7TZ-14489-AA (97)
(International) 1830829C91 removal tool and Shells w/o pins
(International) 1661875C1 Pins
(International) 2501055C1 Pins with 6" wire
one of the ford #s is wrong, I forget which one, not shure on the IH tool and shells, never bough them. the pin and wire with pin #s correct
usually all ya need to do is remove the terminal from the bad shell and insert into the new shell
only rarely have I had to replace the terninal or use the new terminal with wire.

 

[OLDBULL8]

To bad you didn't read this post first. http://www.oilburners.net/forums/showthread.php?t=50925
Yes it can be done.

 

[fuzzydog]

To bad you didn't read this post first. http://www.oilburners.net/forums/showthread.php?t=50925
Yes it can be done.

hmmm, I just read it now (thank you) and I could still return the vc gaskets and harnesses as I haven't used them yet (things ground to a halt last night when the only Autolite glow plug left the tip in the head)

Not sure what I gain by combining the harnesses though?