I put a banks tuner in my 04, 6.0 before I had 10Kmiles on the truck and I was reasonably happy. It did not spin tires or perform anywhere near where I expected but it was significantly quicker than factory and I went from about 15mpg to 17mpg. All good.

Well 140K later the transmission finally started to go. I looked up my problems on the forum and it sounded like it could be just a couple of solenoids in the tranny but after bringing it to a "diesel specialist" it was reported to be in need of a rebuild. Given the hard service and 50K of those miles towing I figured I did pretty good.

Don't get me wrong, I have had to replace the FCIM, glow plug relay, wiring harness and most of the other typical problems including an injector but took it all in stride & it seemed reasonable.

At this point I'm figuring; I love the truck and would like to do a bit better than the banks and get a better tuner along with the tranny rebuild. Ive also noticed my mileage is back down to 15mpg, so I inquire about removing the banks and installing whatever they recommend which turns out to be an SCT.

Well that starts a whole discussion about the EGR delete and the improved mileage I can get from it, a better air cleaner filter ect.. next thing I am looking at doing the head studs, turns out the heads are cracked so they get replaced. While we are in there, all new glow plugs and sure enough the injector test show ALL of the injectors are outside the performance parameters so they all get replaced too. He says the turbo is good and just cleans it up but we add in a new oil cooler, an RV billet TC & some heavier upgrades to the tranny (that I originally went in for expecting a solenoid replacement) and of course a new oil cooler and I'm 13K into what I figured to be pretty bullet proof power with an expectation of improved mileage and hopefully as much or a little more zip than I had with the banks.

It comes back a dog. A few days of hard & untimely shifting with what seemed to be several steps backwards in power/boost and by the time I'm at the end of my first tank of fuel its looking like I'm getting 10mpg. Well I figure its just the tranny having to break in and the specialist tells me the tough shifting is the tranny learning the new strategy. I go easy on it for the next 3-4 tanks of fuel and it does not get better.

I call up and let him know I'm struggling but figure it just needs a tuner tweak or whatever and he will make it right when he gets around to it. I don't use the truck regular and I travel alot so it is about a month or so before I get it back to him & he goes through to check all the standard stuff related to compression & codes ect... & flashes the truck for good measure.

He tells me it is all correct, the issue is with the tuner & I need to find the right tune for my truck. Good luck & see ya later. WTF?

I don't know jack about how to find the right tune for my truck. Isn't that better done by a diesel tech with a Dyno? Or somebody that knows this brand of tuner? I called SCT and they ran through how to go between the programmed tunes I have; factory, tow, street and performance.

They gave me a general disclaimer that their product does not necessarily improve performance but I felt the tech was surprised at the low MPG. I have yet to really push the truck figuring it could use a couple thousand miles of break in before I really put the hammer down so I cant speak for the power 100%. Power isn't bad but not as good as it was with the banks.

Can anyone here in the community help me manage my expectations of fuel economy? I was hoping for 17-20, is that just dumb on my part?

Not sure what to try next? Switch up the tunes I have and see what happens? Custom tune ?(I'm in Mass & have no idea where to get that done?) Remove the tuner all together and see what I get? Put the banks back in? Different tuner?

It has been 4 months since I cut that check for 13K and each month that goes by I feel I'm further away from getting help. I have never pushed hard or thrown a tantrum but I'm not feeling the love from this Diesel Specialist and figure I'm on my own at this point. I would greatly appreciate any insights from the FTE guru's on where to go from here.

Sorry for the novel

 

Well I have a sct tuner and I can say that its far from disappointing. I think you have somthing going on there. Maybe a exhaust leak or turbo isn't functioning fully. I think this mechanic saw a guy that wanted new life in his truck. And was willing to pay for it all. Seriously all injectors were replaced? My truck has a few of the factoy originals. 210k and 10 yrs later, all trucks get diff mileage. My truck gets 15-17 mixed milage and abour 17-19 highway. Ive seen sone say 20-22 but thats hard to stomach.

 

Yes all the injectors. He showed me the report and each one had some aspect of the three measurements that were outside the spec parameters.

At that point in the re-build, I would not have just replaced 4 anyway. I would hate to come back in 3 months and have to rip the whole thing apart again for the injector I didn't change...

 

Also to note: I love my truck and its power!!!

I'm not a hater over the cost of freshening that bad Larry up but I want to find a solution to get my mileage in check. 15mpg I could live with. 17mpg I'd be proud. 20 & I'd be buying lap dances for everyone!

Glad to hear the SCT serves you well. Which tune do you run?

 

I have a 2006 F250 6.0 diesel with 72,000 miles.

It gets about 17-19 mpg city/highway mixed and about 19-21 highway. (no load, North Carolina "mountains" (actually what we call foothills).

I performed two manual measurements and the computer stated milage was within 5% of measured mileage.

So 20-mpg highway (easy foot trying to get the best gas mileage, no load) is achievable.

I run a SCT tuner and my mechanic programmed the tunes. I will ask him where and how he developed/programmed the tunes and get back to you if you are interested.

 

I run the canned SCT tunes and they really wake the 6.0 up, I agree something isn't right with your truck you should see a marked difference between stock and tuned. Do you have some way to monitor live data on your truck? Like scan gauge II or one of the smartphone apps like dashboss for IOS devices or torque pro for android? In order to help you out we will need to know some specific data points.

 

Interesting stuff. How did you get your manual measurements on mileage?

I would buy a monitor or gauge or whatever is needed to get the data. Any recommendations on something specific? Maybe something that SCT makes so its all compatible?

 

sorry, I did not digest dash boss ect... you were pretty specific there! I'll check it out asap.

 

Monty, yes I'm interested in how he developed the tunes. Do you know if you are running box tunes or customs? Have you guys used other tuners? Banks, Bullydogs?

 

SCT is the way to go on these trucks. My preference on the gauges is the edge insight CTS but the Dashboss can do more and do it for less money.

 

You take miles driven and divide it by gallons of fuel at the pump.

So if you went 100 miles and it took 10 gallons..... 100÷10=10 so manually, you got 10 miles to the gallon.

 

I do not know much about the tunes but I believe the mechanic that repaired my truck, who also has a 2006 F250 6.0, had his truck dyno tested and developed the tunes during that process (I believe). I will find out.

My gas mileage verification process is as follows:

(1) Fill up tank;
(2) Reset tripometer;
(3) Reset computer generated average MPG reading;
(4) Drive in whatever conditions one wants (city, highway, no load, etc.);
(5) Eventually fill up tank and note the gallons used;
(6) Note tripometer reading (miles driven) and calculate the average MPG;
(7) Note the computer generated average MPG; and
(8) Compare the calculated average MPG with computer generated average MPG.

Bellow are my Mileage testing notes

MILEAGE
City MPG: 17-19 mpg
Highway MPG: 19-21 mpg (70 mph / mostly flat but some hills, no load)

Last time I check mileage after 1 hour highway drive : 23 MPG
(I merged on interstate, achieved cursing speed of 70 mph and then put on cruse control and reset computer mileage reading - after 1 hour the computer indicated 23 mpg).

I VERIFIED THE MILEAGE SENSOR

First check: "CITY MILEAGE" LOTS of idle time (at least 1 hour while radio was installed in truck and 10 degree weather)

NO LOAD
Miles: 58.1
Gallons: 4.7
Measured Mileage : 12.4
Lie-o-Meter Mileage : 11.8
Percent Error: 4.5%

Second Check: Mixture (20% city, 40% country with some stop signs, 40% interstate)

NO LOAD
Miles: 40.7
Gallons: 2.1
Measured Mileage : 19.4
Lie-o-Meter Mileage : 19.6
Percent Error: 1.1%

The "Lie-o-Meter" seems accurate for the limited measurements above.
(Note: full tank of gas in all test - of course - thus, if the Lie-0-Meter becomes more inaccurate as the tank empties my testing would not detect such problem)


MODS

By the way, below is a list of the MODS I had performed on my truck when the head gaskets failed. Uncharacteristically lucky for me, I found an excellent 6.0 mechanic that also owns a 6.0 and tries to tweak out every ounce of performance for his truck via mods and tunes and he set me up right.

Not sure any one mod is responsible for the MPG performance.

Engine Repair Date: October 18, 2013
Repair Miles : 67,878 miles
Current Miles : 72,500 miles

01. Machined heads - Heads Milled: 12/1000 (0.012) and 14/1000 (0.014) -- No valve work done - just milled heads;
02. OEM head gasket;
03. New OEM push rods (0.050" shorter than original);
04. New ARP head studs;
05. EGR Delete;
06. Replaced oil cooler;
07. Replaced HPOP STC fitting and dummy plugs;
08. Installed 4" MRRP Full Exhaust (removed the "save the world" catastrophic converter [I know, it is catalytic converter but I like catastrophic] );
09. SCT LiveWire TS with EGT probe at manifold;
10. Flushed and replaced coolant and replaced all fluids; and
11. New batteries.

 

What Injectors?? Bigger??

Does the turbo Leak??

What Boost levals do you see??

Does it still drive Bad??

Just bad MPG

Sorrey man that's a Ton of Coin for a Messed up truck But Hang in there this Forum will get you figured out

 

So did you do the EGR delete? I use the Scan Gauge II there was a post on the front page for less ,I picked mine up at Auto Zone for 160.00, I could of done a lot better but when it was needed, screw it I Bought it. you need to look at some things FICM mp ,lp, vp. ( main , logic, Vehicle). EGR valve if still in places needs cleaning ,IAT2 will be sooted, and MAP connection to Intake the little Nipple and port gets clogged, next will be the EBP and Tube, make sure the tube is cleared and the hole in the senser is open , When you get A Gauge we can Monitor these to find out if one or the Other is bad. Take a look at the CAC boots make sure they are not leaking air with loss of boost, and Keep your OEM AIR cleaner just change out the Filter with OEM your Turbo will Thank you . Are you sure your Braking system is not dragging this will be most common fuel consumption in our trucks.

 

There has been many of a so called good mechanics screw up a 6.0
then turn around and charge the costumer for there lack of training
on this engine. I know and it sad but it still is going on.
It comes from some of the following things. Don't know, Don't want
to take the time to diagnose is right,greed and just plain old stupidity.
Mechanics range Smart and talented 10~1 ... well you get the idea.

Lets fix this.

First thing is a tool to monitor what it's doing. There are many good picks out there.

After that you need to get the truck running right in the stock configuration.
Once you have that settled then you can put the tunes on.
I run and really like what Matt has at Gearhead Automotive Performance
I can with the non-stud SRL break the tires loose when already rolling
and make a black tire smoke cloud. I did that when merging onto the freeway.
You should of seen then scatter.
Yes I loose a little MPG but that is my foot more than anything else.

Sean