This is on my e350 van, 05 with a 5.4. Just rolled over 100k and I was in VA in the hills with a load and I lost power. Barely (like 10 mph) made it to the top and then it was fine again. Did this every time I needed to climb a hill and was loaded. Will not lose power when empty, just loaded. I went to a chain autoparts store and had the tart there pull the code for me and it was a p0191. He looked it up and told me I had a bad fuel pressure sensor and that it was a dealer only item. So, off I went a few hundred more miles and it was still a problem, I went to a real parts store and I changed the fuel filter at the first chance and it was bad, looked like mud coming out of it. I also put in dry-gas and ran premium the rest of the trip. It was much better, but will still, ONLY WHEN LOADED, will lack power, like the engine is losing fuel.
The 191 code is a fuel rail pressure sensor, my question is are these sensors prone to failure or is this a diffrent problem ?

 

Not sure if that is really the problem but here is a link to the removal/installtion of the senor.

2005 F-Super Duty 250-550 Workshop Manual

You may also want to look at your filter again. If you have that much gunk in it when you replaced it you may have got something in the tank and the new filter is plugged again.

 

I changed the filter a second time as soon as I got home and it was clean. thanks for the link.

 

How is your fuel pressure?

 

I'm lost here.

I've had my truck at the Ford Dealership for the past 2 weeks now. I took it to them due to code P0191 showing. It was running poorly, black smoke from exhaust, sputtering. The guy i bought it from told me the board was bad. I decided to try and fix the cheaper things first. So I replaced fuel pressure sensor. FPDM is in good shape. All compression test on injectors were ok. The dealership scanner pulled up like 10 codes my friends shop didn't (he had a very expensive scanner). All the codes they told me came up pointed to the Throttle body (which I had cleaned a week before). So they ripped me a new one charging me $700 for a new throttle body. I went and picked my truck up that day....drove fine otw home....next morning check engine light back on, same code showing, and same symptoms happening intermittently. Any ideas?

 

If you are getting a code for out of range fuel pressure, you may need to monitor the fuel pressure real-time to see what's happening there. Depending on the mileage of the truck and how often the fuel filter has been replaced, I would suspect that the fuel pump may be starting to die and can't maintain appropriate pressures at higher flowrates that are required for running at higher loads. You may also need to replace the fuel filter.