TSB 07-8-9

6.4L DIESEL ENGINE - LACKS POWER, LEAKS FLUID FROM EXHAUST PIPE, ABNORMAL TAILPIPE SEDIMENT, WHITE SMOKE, EXHAUST SMELL, AND MIL ON

ISSUE:
Some F-Super Duty vehicles equipped with the 6.4L diesel may exhibit one or more of the following concerns: lacks power, leaks oil, fuel or coolant from the tail pipe, abnormal tailpipe sediment, white smoke or ash, exhaust smell, knock or rattle, elevated idle, surge, crankcase oil level over-full, MIL On, DTC's P0087, P2291, P0263-P0284, P0300-P0308, P1336, P132B, P2262, P2263, P244C or P244D.

ACTION:
To diagnose and correct the concern, refer to the following Service Procedure.

SERVICE PROCEDURE

NOTE:
DO NOT START ENGINE

Evaluation, Inspections, And Checks

1. Retrieve KOEO diagnostic trouble codes (DTCs).

2. Check oil level. Remove and clean dipstick. Reinsert into dipstick tube only until dipstick handle reaches top of dipstick tube (Figure 1).

NOTE:
FIGURE 1 DEMONSTRATES DIPSTICK POSITIONING FOR OVER-FULL CHECK. KEEP DIPSTICK HANDLE OFFSET OF CENTRE TO PREVENT IT FROM FULLY SEATING. IF OIL LEVEL IS BELOW THE MAX MARK, OIL IS NOT OVER-FULL.

3. Check coolant level.

4. Check fuel quality.

5. Inspect tailpipes for abnormal sediment; for example black soot, white ash, oil, coolant, or fuel.

6. Inspect vehicle for coolant, oil and fuel leaks at the following locations:
• Tailpipes
• Up-pipe joints
• Exhaust manifolds to cylinder heads
• Exhaust manifolds to up-pipes
• Charge air cooler system and air inlet system

NOTE:
PROCEED ONLY IF ENGINE OIL TEMPERATURE (EOT) IS LESS THAN 150 °F (66 °C).

NOTE:
VALIDATE INTEGRITY OF ALL EXHAUST GAS TEMPERATURE (EGT) SENSORS WITH POWERTRAIN CONTROL/EMISSIONS DIAGNOSIS (PC/ED) PINPOINT TEST (PPT) RC5 AND RC6 BEFORE PROCEEDING.

NOTE:
IF REPAIRS ARE PERFORMED AS A RESULT OF THIS TSB, CHECK DIESEL PARTICULATE FILTER OPERATION. SEE PC/ED, SYMPTOM CHARTS, NO DTCS, CHART 8.

Repair Directions

• Section A - If the following DTCs are present P0087, P2291, P0263-0284, P0300-P0308, or P1336 or if observation of external fuel leaks, for example, wetness around exhaust manifolds or over-full oil level indication.
• Section B - If the following DTCs are present P132B, P2262, or P2263 or observation of oil leaks (aside from over-full oil level) or oil level is low.
• Section C - If coolant low or observation of coolant leaks.
• Sections A, B, and C - If only abnormal sediment in tailpipes.

SECTION - A

Fuel System Diagnostics

NOTE:
IN CASES WHERE ENGINE OIL HAS BEEN DILUTED WITH DIESEL FUEL AND ALL REPAIRS ARE COMPLETE, RELEASE THE OIL FILTER CAP ALLOWING OIL TO DRAIN TO OIL PAN AND KEEP FILTER, DRAIN THE OIL FROM OIL PAN AND FILL WITH NEW OIL. TIGHTEN OIL FILTER CAP AND RUN ENGINE FOR 10 MINUTES. FINALLY, CHANGE OIL FILTER AND OIL AGAIN.

1. If oil is not over-full - go to Step 9.

2. If oil is over full, drain and fill crankcase with new oil setting the level to the middle of the hash marks.

3. Remove valve covers; refer to Workshop Manual (WSM), Section 303-01.

4. Remove lower charged air cooler CAC hose. Inspect for fuel and oil contamination. Clean as required and reinstall.

5. Start engine and use caution when looking for fuel leaks around supply tubes and injectors.

6. If no leak is found run the IDS high pressure fuel system test and inspect for a leak during the test.

7. If no leak is found turn the engine off and use a hand held mirror to inspect for cracks on the underside of the fitting boss. (Figure 2)

8. Replace any leaking components and verify leak has been repaired while running IDS high pressure fuel system test - KOER.

9. Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check.

10. If fuel quality is poor, drain all fuel and replace with known good ultra-low sulfur diesel fuel.

11. If no DTCs were stored in pending or continuous memory go to Step 13.

12. Is there abnormal sediment in tailpipes or fuel evident?
A. No - Complete PC/ED worksheet and applicable PPT tests for the codes retrieved.
B. Yes - Go to Step 13.

13. Is there abnormal sediment in the tailpipes?
A. No - See WSM for diagnosis.
B. Yes - Go to Step 14.

14. Perform IDS Relative Compression Test.
A. Problem Identified - Repair as required.
B. No Problem - Go to Step 15.

15. Perform fuel supply system pressure check (low pressure system) - KOEO.
A. Problem Identified - Repair as required.
B. No Problem - Go to Step 16.

16. Observe IDS injector fuel trim.

NOTE:
FUEL TRIM WILL DEFAULT TO ZERO WHILE EXHAUST AFTER TREATMENT SYSTEM REGENERATION IS ACTIVE. (Figure 3)

17. Observe IDS Power Balance. (Figure 3)

18. Perform Enhanced Power Balance. (Figure 3)

19. Compare results in Steps 16-18.
A. Low fuel trim may indicate leaking injector.
B. High contribution may indicate leaking injector.
C. Elevated contribution in comparison to other cylinders while cancelled may indicate leaking injector.
D. Excessive pull-up by subsequent injector may indicate leaking injector.
E. An engine knock that is lessened when a cylinder is cancelled may indicate a leaking injector.

20. If no root cause is determined in Steps 1-18, perform IDS high-pressure fuel system check and repeat Steps 1-18.

21. If no root cause is determined, replace horizontal fuel conditioning module (HFCM) and on-engine fuel filters.

SECTION - B

1. Do not crank engine. Perform KOEO and observe turbocharger actuator. Does the actuator move at key on?
A. No - Ensure turbocharger is above 32 °F (0 °C). Move truck to a warm location and repeat test. If turbocharger actuator does not move and is above 32 °F (0 °C), perform PC/ED diagnostics.
B. Yes - Step 2.

2. If no DTCs are present, go to Step 4.

3. Is oil or abnormal sediment evident in tailpipes?
A. No - Complete PC/ED worksheet and applicable PPT tests for the codes retrieved.
B. Yes - Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check and repair as required.

4. Is oil or abnormal sediment evident in tailpipes?
A. No - Perform WSM, Section 100-04 - Noise Diagnostics.
B. Yes - Perform WSM, Section 303-04D - Turbocharger Bearing Clearance Check and repair as required.

5. Remove lower CAC hose. Inspect for fuel and oil contamination. Clean as required and reinstall.

SECTION - C

Perform WSM, Section 303-03 - Diagnostics for EGR cooler and engine internal coolant leaks.

WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

 

This has been out for a bit.... Haven't heard of any that have reported this on the forums....

 

This maybe a simple question but is there a way to decode the date of the TSB?

 

Not that I know of.... Numerical # I think is simply a way to categorize the TSB's.....

 

Well it may not be a major problem, I would guess it is no big deal.

 

I agree. but people love negativity.

 

I think there will be a lot of att. with the 6.4 to make sure there are no mods, anyone who thinks ford is not on the watch is kidding there self. the 6.0 is still eating fords lunch in warranty claims. even though there are less problems with the 05,06,07 they are still having problems as my tech said the 6.0 is just a poor design, meaning the egr and all the smog junk.

 

the EPA is a bad design

 

Most Government agencies are bad ideas.......Fix the Imigration issues, Quit trying to screw with my Guns and leave my Diesel Truck alone!

Ok , now I feel alittle better!

The American Indians know 1st hand what happens when you don't control Imigration!