Ok, I originally posted a video of an idle surge problem I was experiencing. I was never able to solve the issue, but instead learned to live with it. Now the problem has intensified and the truck is stalling unexpectedly. Here are the issues I have been experiencing lately:
-When starting the truck in the morning (approx 38 degrees) the truck starts right up and then dies after about 10 seconds. It would repeat every time I try and restart, but I get impatient and give it some throttle for a while to get going.
-After the truck is in drive, it will stall when coming to a stop or slowing down to make a turn. This issue will not go away until the truck is at optimal temperature.
-Even with the truck at normal temperature, if I sit idle for a while in drive with a foot on the brake pedal, the engine will nearly stall and then rev back to life. Once it does this, there is a 50/50 chance of the truck stalling once I start accelerating.
So far, I have pulled the FCA off and sprayed the ports with wd-40 with no success, I have been running diesel clean at every fill up, and I have changed the fuel filter several times. I am leaning toward an electrical problem since the issue is sporadic and I can cause the engine to surge in park by cycling me A/C on and off. To the best of my recollection, the engine surge began when I hooked up alligator clamps to my battery to operate a motor that raises a 10k gal water tank (empty of course). I have checked voltage of both batteries with a multimeter and checked alternator voltage at the battery with the engine running. I have not load tested the batteries or checked voltage directly at the alternator. Any help on this would be a life saver, starting to get really frustrated.
If it makes any difference my trans and torque converter were rebuilt 6 months ago by a professional mechanic.
Thanks!

 

the fca could just be bad, the cp3 could be going bad or your fuel pump. what is you fuel and fuel rail pressure when this happens?

 

I am not sure I have the proper gauges to test the fuel pressure at the rail? Are there any special tricks that you know of to test this? If it was a fuel related problem wouldn't it be fairly consistent every time I drive the truck, or could it be off and on the way it is right now?

Thanks

 

With engine running,
do the voltage readings again before the surge and do it again while surging and post it for further response.
I need to see driver side battery voltage and passenger side battery voltage, before surge and while surging.

 

Suspect electrical issue or fuel issue.

 

I will try this when I get home. The surge is off and on, so hopefully it is surging when I get home. (Never thought I would say that)

 

So I was trying to accomplish some additional voltage testing last night but lately, my truck has been bypassing the surge and goes straight to the stall. Gonna have to figure out another method

 

Mine acted like that it was FCA part was about $116.00 from Frieghtliner

 

Ok, so it has been a while since I have given an update but I wanted to close the loop in case anyone else is experiencing the same issues. Took my truck to a diesel mechanic and they informed me that the problem is fuel leaking by the injectors. I was shocked because I figured that this would make the truck run rough on a consistent basis and I would be experiencing excess exhaust smoke. The injector replacement job would be at least $3,000. Before I went to that extreme, I figured I would throw an FCA at it in hopes it would solve my issues. Lucky me! the FCA solved all of my stalling and surging problems (cheap and easy). It is nice to finally have my truck back up and running normally. Thanks for everyone's help, I dont know where I would be without these forums.

 

What is fca

 

The FCA is a fuel control actuator. Easy and cheap to replace. $120 part and (3) t-25 bolts. From what I have been researching, this is a pretty common failure.

 

You can test the FCA by adding about 8 oz of two stroke oil to a tank of gas..if the idle surge/stall smoothes out, then it IS the FCA.
Like others have said, it is cherap and easy to replace.