sounds like your egr cooler. i had baught a 04 brand new, traded it in for some thing else. i went 50,000 miles rebuilt the turbo 3 times, 2 sets of injectors, and blew the egr cooler 400 miles from home.that truck will keep u on your feet, thats for sure. i've had nothing but trouble with the 6.0L, 7.3 all the way

 

The 6.0L are problematic to say the least. I had numerous problems with mine (Some were my own fault with the power adders, some were FMC). The 2005 and newer MOST of the bugs were worked out of them. Still there is turbo problems. How long was the truck sitting at the dealership? The turbo are known to corrode if sitting. EGR is the worst thing in the truck. You can get a tuner to program it to stay closed all the time. I had mine welded closed. If you decide not to keep it closed, at the very least pull it and clean it often. My buddy bought his truck the same time as I did. He used his harder than I did and he has had minumum problems. The injectors I believe were improved in the 2005 and newer trucks also. HPOP was also cuases of a lot of head aches as well. Not trying to scare you, just trying to help. I use to hang out in the 6L forum everyday.

 

I forgot to post my fixed issues when I took my beast to the Ford dealer. They replaced the center support for the turbo and O rings. Both were covered under warrantee. Everything done and said...$1800.00 . Two days went by and my fuel guage was registering empty..in fact past empty. I shut the truck off two times and drove it for a mile or so. Shut it off one more time and it registered a half tank. Engine light was on...here we go. Still had some power loss when taking off...but I took the truck back to Ford. The codes were pointing toward the fuel system. The tech dropped the fuel tank and replaced the fuel sending unit. Bingo....it now runs like it should.

One question for you guys....I used my first tank of fuel (just bought the truck 3 weeks ago) and my mpg sucked. My average is 13mpg....with a PSD I would figure it would be better than that. What do you suggest I do to improve the mpg? Flash the code??? I don't want to void the warrantee since it has 81K on a 100K warrantee.

Any thoughs.....

Thanks guys!!!

Mike821

 

O-rings on what the injectors. I am having the same problem. Thanks