05 F250 6.0 less than 60K miles. Two turbos replaced under warranty (1st failed at 35K the next at 47K). Recently had over boost code p0234,wrench light went on and truck went to limp mode. Dealer suggested new turbo but 3 days outa warranty so on my nickel. So I had Local certified ford mechanic that does work on side look at it. He recommended cleaning the turbo (hoping that would work) and new oil drain tube, I also had him install BPD oil cooler and EGR to prevent future known issues (thought truck would be all done). About 50 miles after the work was done I installed new EDGE insite that showed P0299 code under boost. EBP on edge showed 2psi KOEO. So I replaced the EBV sensor and tube. EBP still at 2PSI after replacement and PO299 code also came back. About 50 miles later the P0234 came back with wrench light and limp mode again. Was watching the boost and it went to 32 and engine light came right on. Looks like I need a 3rd turbo but the Million dollar question is why are these turbos failing every 10 to 15K and what can I do to stop it from happening again. PS I already drive it like I stole it and use fuel additive (just to rule that out). Appreciate any help, ready to drive this truck of a cliff!

 

What are the readings KOEO for BARO, EBP and MAP? Then same at idle? They should be within .5 or so of BARO at KOEO.

 

Map = 13 idle 13 KOEO, baro = 13.5 idle, 13.4 KOEO, EBP = 3 Idle 0 KOEO - These readings are from my edge insite CTS. Also EBP never gets above 25 wide open.

 

about 30psi, wrench light comes on to protect from over-boost, p0299 is under-boost... which you already know. EBP looks fine, what is the VGT showing at idle and with heavy foot? MAP is good, BARO is good, your at 1500+ elevation? Is EGR dirty? Can you get the turbo to fart? Get into the throttle hard and let off fast, should produce a fart and if it doesn't... you probably need to clean the turbo, something you could do yourself.

How often do you drive the truck, drive until fully warmed up? What is your ECT running after fully warm? 60K on an 05' truck, you don't drive it much and then when, just towing?

 

With all of the turbo replacements have they ever replaced the VGT valve? The new turbo's do not come with a new VGT valve.

 

Yes Im at roughly 2K above seal level, VGT around 500 at idle and then averages around 800 to 1000 when I'm pushing it. Ive never seen VGT above 1100. EGR is brand new Bullet proof diesel, less than 150 miles, The turbo was also just cleaned at same time we did the EGR. Right now the only option seems to do my 3rd new turbo in less than 40K miles. I was also considering doing the VGT valve (as mustang 309 suggested) as i don't believe its ever been replaced. On driving i use this truck primarily as a hunting truck and to take motorcycles to desert so it only gets around 5K a year. But i make sure to get it out once a week and drive it hard. I just can't imagine that normal turbo life is 14K miles. It seems like there must be something i need to do to keep this from happening so often??

 

The VGT value is 15-85% if you watch it while driving you never want to see it stay at 15 or 85%, at steady state driving it should be in the 40 to 60% range, if you see it going to 15 or 85% and staying there the turbo is likely sticking. At idle and up to temp ( 185*+ EOT ) you should see it in the 70's. The VGT% is a commanded value and the PCM will drive it in the direction it needs until it reaches the boost value its looking for and if it doesn't get there it will drive it to its max value which is 15 or 85% depending on what it needs.

 

that makes senses i will take it out and see what the VGT is. One other question, my ECT and EOT seem a little high, they run normally around 200 and very close to each other, less than 7degrees, after they get up to temp. But on very long up hills climbs on days were out site temp is 90deg plus is see EOT max out at 230. Is that normal when not towing?

 

Seeing 230* EOT while towing up long grades is normal.

 

i would consider 230 a little high especially when unloaded.
when EOT is 230 what is ECT?

 

ect is running generally between 0 and 10 degrees less than EOT. I think when EOT is 230 ECT in low 220"s. Keep in mind that I have the bullet proof diesel oil cooler that is air cooled.

 

i never see over 210 EOT when unloaded. even romping on it up long hills.
this may be because of your BPD cooler.

also, are you using a factory intake and filter?

 

Four turbos in less than 60,000 miles is one of the main reasons Ford did a buy back on my 05.

 

how did you get ford to do the buy back? I called them and they just gave me the number of the better business bureau. I pushed hard. This last turbo (one I'm about that replace) was 3 days out of warranty and they told me to pound sand. Even when the code was thrown in warranty they would not even budge.

 

yes kept the factor filter and intake. everything I've read seems to point to not changing it.