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What causes your 1996 power stroke diesel to idle rough at times but not all of the time?

A rough idle in a 1996 Power Stroke 7.3L diesel that's intermittent, meaning it doesn't happen all the time, points to several possible culprits. It's unlikely to be a single catastrophic failure; instead, it's probably a combination of factors or a problem that's only manifesting under certain conditions. Here's a breakdown of common suspects:

Fuel System:

* Fuel Filter: A partially clogged fuel filter restricts fuel flow, leading to inconsistent fuel delivery and rough idling, especially noticeable under load or when the engine is warm. This is a relatively cheap and easy check.

* Water in Fuel: Water can cause a rough idle and even stalling. It can also promote bacterial growth in the fuel tank. Check your fuel/water separator.

* Injector Issues: A sticking or failing injector can cause a rough idle. This is more likely to be a consistent problem, but a partially clogged injector might only act up under certain conditions (temperature, load). This requires testing and potentially injector replacement or cleaning.

* Fuel Pump: A failing fuel pump might not be supplying enough fuel at idle, especially if the engine is demanding more (e.g., accessories turned on).

* Low Fuel Level: A very low fuel level can sometimes cause fuel starvation, leading to rough idling.

Ignition System (Though less likely on a diesel):

* Glow Plugs: While glow plugs are primarily for cold starting, faulty ones can contribute to a slightly rough idle when the engine is cold or under certain conditions. This is less likely to be the sole cause of an intermittent rough idle.

Air System:

* Intake Air Restriction: A partially clogged air filter can restrict airflow, leading to a rough idle. This is a relatively easy check.

* Vacuum Leaks: Leaks in vacuum lines can affect the idle air control system (if equipped), leading to inconsistent idling.

Other Potential Causes:

* Engine Sensors: Various sensors (e.g., crankshaft position sensor, camshaft position sensor, MAP sensor) feed information to the engine's computer. A faulty sensor can cause the computer to miscalculate fuel delivery, leading to rough idling.

* Wiring Harness: Damaged or corroded wiring can disrupt the signals to the various components, leading to intermittent problems.

* Harmonic Balancer: A failing harmonic balancer can cause vibrations that manifest as a rough idle.

Troubleshooting Steps:

1. Check the easy stuff first: Fuel filter, air filter, fuel level. These are the cheapest and easiest checks.

2. Inspect fuel lines and connections: Look for leaks or cracks.

3. Check the fuel/water separator: Drain any accumulated water.

4. Listen carefully: Is the rough idle accompanied by any other noises (knocking, ticking)? This can provide clues.

5. Scan the codes: Use an OBD-II scanner (capable of reading diesel codes) to see if any diagnostic trouble codes (DTCs) are stored. These can pinpoint potential problems.

6. Professional help: If you're not comfortable diagnosing and fixing these issues yourself, take your truck to a mechanic specializing in diesel engines. They have the tools and expertise to diagnose the problem accurately.

Remember that diagnosing an intermittent problem is often more challenging than a consistent one. A methodical approach and careful observation are key to finding the culprit.