So I'm up sh*t creek without a paddle here. The APPS was bad on our 2004 2500 5.9L (229k miles). It would cut out, if you let off the pedal, you could "catch" it again and eventually get up to speed - basically sounded like an 18 wheeler shifting, but it's an automatic. I ordered a new APPS, took all this crap apart (If you watch the video they took 3 bolts off but I found it easier to remove the radiator hose and get a small screw driver in there - but I have small hands too), followed directions included to a T. Back probed the #3 pin to exactly .55 V, tightened it down, retested, still .55V (as instructed) Shut the key off. Turned it on, depressed pedal slowly to the floor and let up slowly, then turned the truck off. Started the truck and I only have idle - completely dead pedal.
It did throw the codes P2121 and P2122 related to the APPS/TPS being bad.

Any ideas? I'm thinking my new APPS is defective or I f'ed up somewhere with calibrating it. All assembled I back probed that pin again and it's still at .55 V as suggested by the manufacturer instructions. I knew it all came apart too easy to work right the first time, but I've pulled it back off 3 times now to double check everything and it's not working. So aside from just going down to replace the whole thing, plate and all since OReilly doesn't seem to have just the sensor, is there anything else I can try?
Trying to get this sucker going for a trip I have to make tomorrow, it's over 100 here and the AC in my 2003 3500 isn't working (that's another story, threw codes for the fan clutch, which was slower than normal, and I replaced the entire thing but still no AC and high side pressure is high, low side pressure is normal), so would rather take this one for creature comforts.

 

I didn't think that year diesel had an electronic TB or pedal...

 

Sure does, my 2003 3500 and the 2004 2500 both have them (both are the same motor, 5.9L "vin C" HO models). The 2003 might have a different one, there are two types, but I haven't taken it off because that truck just rolled 100,000 miles - it's my daily driver, I just got lucky and found one with basically no mileage on it.


No clue what the deal was with that sensor, but replaced the entire plate with sensor included and truck ran great and did a 200 mile trip on Saturday. I'm thinking the original sensor might have had a defect, as I had no problem installing the new one and calibrating it, literally took under 30 minutes to put the new one on and be able to peel out in the driveway.

 

Learn something new every day lol

 

Tell me about it, I learned that they have electric fans that aren't belt driven like every other vehicle I've ever owned, lol. Boy do I miss the days of less electronics, my 1984 1/2 ton doesn't have half the crap these newer ones do. Then the Cummins is a new beast to me, previous to these I had a 7.3 powerstroke, and none of it is the same at all.

 

You're lucky you have a 5.9, the controls, etc on the later 6.7's would just **** you off lol

 

True, but I also have a cracked dash and a bum air blend door I don't want to tear the whole dash apart to mess with - so AC and heat to the face only!
But I've been there, we traded in a 2009 1500 hemi for the diesel, I love some actuators under the dash...said nobody ever.

 

Feel your pain there. Replaced my dash when my heater core went 4yrs ago. Did the blend door & evaporator while I was in there. Had to do the recirc door couple months ago.