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Thread: 2006 5.9L Cummins - Surging?

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    jetursi's Avatar

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    2006 5.9L Cummins - Surging?

    I'm attempting to help my brother fix his 2006 5.9L Cummins; the engine is stock other than exhaust, intake, and an EFI tune.

    No idea what tuner, though; it has a complete built ATS Trans and a FASS 150(or 100)

    It started surging this summer; while towing a ski boat to the lake, it would surge so bad it was almost impossible to drive.

    Mostly would do it while driving at an incline (any gear, any speed)

    We did the usual, cleaned all ground and battery terminals, and checked ECM plugs for corrosion and non.

    This has always been an AZ truck, so rust and corrosion are not likely.

    We then drove it for a get-a hundred miles (empty) with no issues, and the truck ran OK and had full power.

    Next weekend hooked up the trailer and 40min into tow, same thing.

    This time it threw app sensor codes.

    We pulled over and noticed lift pump FASS wasn't running.

    Towed the truck and trailer home.

    We then replaced the FASS pump and then replaced the apps, cleared codes, did the pedal apps relearn, and all was good.

    I hooked up the trailer, and the same darn thing surge was so unbearable we drove back at 30mph for 5 hours.

    I thought maybe the torque converter lockup like the 2nd Gens.

    We then locked the converter with a manual switch and monitored the converter; in lockup, it would surge, but the converter stayed locked (almost felt like no fuel but would build a significant boost); while surging, it would eventually pop out of lockup.

    We are pretty stumped on what to check; the truck has no codes, we checked the app's voltage, and it's good; we checked apps to ECM wire, and it has .02 ohms.

    I called the dealer and had a long talk with the service advisor, and he said he would have to flash it to stock to start diag.

    This can't be done cause someone stole the EFI live.

    He said he might have to replace ECU if they can't flash it.

    It only does it pulling a trailer on an incline.

    It only has 140k on the truck and has BBI injectors replaced last summer.

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    I WILL STAND! AK Bob's Avatar

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    2006 5.9L Cummins - Surging?

    A sticking FCA can also cause surging.

    If possible, try monitoring fuel rail pressure actual vs. desired when surging occurs.

    2014 RAM 3500 (Aisin) 3.73 4X4 Limited Crew Cab Long Bed DRW. Oil Bypass Filter, Fuel Filtration Kit, Cold Air Intake, City Diesel Actuator and 50 Gallon Aux Fuel Tank.

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    jetursi's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by AK Bob View Post
    A sticking FCA can also cause surging.

    If possible, try monitoring fuel rail pressure actual vs. desired when surging occurs.
    I forgot to mention that FCA was replaced last week.

    Can my ALFAobd monitor fuel rail pressure desired and actual one a 06, or do I need a DRB or high-end scan tool?

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    I WILL STAND! AK Bob's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by jetursi View Post
    I forgot to mention that FCA was replaced last week.

    Can my ALFAobd monitor fuel rail pressure desired and actual one a 06, or do I need a DRB or high-end scan tool?

    Sent from my SM-G998U using Tapatalk
    It wouldn’t hurt to try AlfaOBD, but I don’t think so.

    Autoenginuity or a higher-end scan tool would be your best bet.

    Wastegate Solenoid is another possibility, so the ability to also monitor Boost actual vs. desired would be helpful.

    2014 RAM 3500 (Aisin) 3.73 4X4 Limited Crew Cab Long Bed DRW. Oil Bypass Filter, Fuel Filtration Kit, Cold Air Intake, City Diesel Actuator and 50 Gallon Aux Fuel Tank.

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    jetursi's Avatar

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    2006 5.9L Cummins - Surging?

    I'll see what I can do to get my hands on a proper scan tool.

    The truck does have a boost Guage, though boost numbers seem to be expected.

    I suppose it's something to check.

    I had read an old post about the fan clutch shorting out, causing a voltage flair or resistance spike to ECM, causing a surge.

    I tried to find a way to test the fan clutch but haven't found a proper way other than "spin it by hand."


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    I WILL STAND! AK Bob's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by jetursi View Post
    I'll see what I can do to get my hands on a proper scan tool.

    The truck does have a boost Guage, though boost numbers seem to be expected.

    I suppose it's something to check.

    I had read an old post about the fan clutch shorting out, causing a voltage flair or resistance spike to ECM, causing a surge.

    I tried to find a way to test the fan clutch but haven't found a proper way other than "spin it by hand."

    Sent from my SM-G998U using Tapatalk
    I guess anything is possible.

    As a test to eliminate that possibility, you could temporarily remove the fuse when surging to see if it stops.

    Did you check for information on the fan clutch in the 2006 Service Manual?

    https://www.igotacummins.com/manuals...e%20Manual.pdf

    2014 RAM 3500 (Aisin) 3.73 4X4 Limited Crew Cab Long Bed DRW. Oil Bypass Filter, Fuel Filtration Kit, Cold Air Intake, City Diesel Actuator and 50 Gallon Aux Fuel Tank.

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    jetursi's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by AK Bob View Post
    I guess anything is possible.

    As a test to eliminate that possibility, you could temporarily remove the fuse when surging to see if it stops.

    Did you check for information on the fan clutch in the 2006 Service Manual?

    https://www.igotacummins.com/manuals...e%20Manual.pdf
    I did not have a service manual for the truck; thank you very much for that hope that helps.

    I found the test for fan clutch, and it seems pretty simple.

    What are options other than the dealer to have the ECM flashed back to stock or restored?

    Or is it better to get a new EFI live with a new tune in it?

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    I WILL STAND! AK Bob's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by jetursi View Post
    I did not have a service manual for the truck; thank you very much for that hope that helps.

    I found the test for fan clutch, and it seems pretty simple.

    What are options other than the dealer to have the ECM flashed back to stock or restored?

    Or is it better to get a new EFI live with a new tune in it?


    Sent from my SM-G998U using Tapatalk
    Unfortunately, I am not up to speed on EFI tuning, but I assume you will have emissions items to address if you return to stock.

    Hopefully, others will have advice.

    2014 RAM 3500 (Aisin) 3.73 4X4 Limited Crew Cab Long Bed DRW. Oil Bypass Filter, Fuel Filtration Kit, Cold Air Intake, City Diesel Actuator and 50 Gallon Aux Fuel Tank.

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    jetursi's Avatar

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    2006 5.9L Cummins - Surging?

    Quote Originally Posted by AK Bob View Post
    Unfortunately, I am not up to speed on EFI tuning, but I assume you will have emissions items to address if you return to stock.

    Hopefully, others will have advice.
    I don't think 2006 has any emissions items, maybe a cat, but I know there are other sensors DPF, def, etc.

    The truck was bought the way it is now, but I didn't think they had any then.

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    Watch Dog! Corkey's Avatar

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    2006 5.9L Cummins - Surging?

    2007 prior were all post emissions, it could have a cat, but I, for some reason, don't recall.

    I know more about 6.7L than 5.9L;\ I wish I could help you with this.

    I'll do some research on your issue at hand.

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