I need some help. Here is a brief history.

2003 PSD 6L purchased 6 months old. Had numerous warranty related issues related to the engine. Now out of warranty with 190,000km's.

May this year the truck died on vacation. It was the FICM so I replaced it with Swamps FICM.

July this year on road vacation 2 the truck died. Towed again and Ford found it to be cracked HPOP branch tubes and 2 bad injectors. replaced it and under testing the HPOP went. Replaced that with a billet one from Dieselsite. Since the motor was ripped apart had Ford do the River City EGR delete kit and oil cooler replacement. Replaced all kinds of smaller items IPR, gaskets, latest FICM straegy and etc. All this reapir cost me $6G

Called Ford immediately after repairing truck as I had an intermitent squeel in the serpentine belt, boost gauge only hit 20 in liue of 28psi previously, and the truck seems to start when warm after 3-5 seconds, not immediately. Appointment was set for 2 weeks later because of busyness in mine and Ford Schedule. Both Ford and I didn't believe any of these potetnial deficincies or symptoms appeared serious.

I took the truck on hunting trip to have the truck die once again. While towing a trailer at 110km/hr passing a big rig along a curve the truck shut off suddenly with no power. Needles to say a scary situation but I managed to safely roll to the shoulder. Burning smoke was coming from the engine comparatment and into the cab thru the vents.

When I opened the hood there was 2 shop rags hanging off the passenger side tubing, one hangin off some tubing and the other dropped and logged between the manifold and firewal, on fire. I sprayed water as that is all I had to put it out. Took the rags out. Nothing appeared damaged from my visual inspection, but the truck would not start and after 1.5 hrs towed back to Ford again.

Ford called today to say all they could find out was a small carbon depost in the IPR which now the truck starts. All test ran ok. I told them they need to recheck everything as there neglegence and truck fire caused the truck to die, otherwise it was just to coincidental and I want a reliable truck. They will have another senior deisel tech to recheck again yesterday for assurance before I pipck it up again.

As you can see from the repairs and my signature, I have been slowly been "bulletproofing" the truck to drive it until death. I am generally familiar with all the design adn reliability problems associated with this 6L but am prepared to keep the truck. I plan on doing a headgasket and studs when warranted however I am not a power junky and keep it stock mainly with reliability my only goal.

Question:

1 - Can the led to the IPR "plugging"
2 - Is the IPR common issue of sudden truck failure under load?
3 - Is there something else happing
4 - What would you do if you were me or any suggestions.

Any suggestions would be appreciated particulary from the guru powerstroke guys on this forum.

 

I had debris in my ipr causing a shut down on decel and it wouldnt restart. It came after I had the oil cooler out of the truck. You must be very careful to make sure the valley is free of debris when it is apart.

 

Thanks Joetech as what you experienced makes sense. But would debris plugging the IPR result immediat;y after repair?

Since the repair I put 800km of lots of small <15km city trips and then this 150km long road trip when the truck died which coincidently at the same time the shop rag lit fire, which makes sense as the truck previously was never warmed up enough for the rag to burn.

 

It has been noted from people doing the EGR delete that their boost also dropped to 20 lbs. There have been a number of posts about this....do a search if interested.

 

Thanks BP. Ford indicated today they no longer specify maximum boost but expect boost to be 20-24psi which there scanner is registering. They also indicated the EGR delete has shown marginal loss of boost.

The only problem I have is that my truck stalled again and Ford beleive the plugged IPR was likley due to contamination entering the valley during the EGR delete and cooler replacement. They didn't admit to the shop rag lighting fire as they stayed silent but did say all costs associated to fixing the truck and retesting and warrantying all work including future diagnotics if problems persists will be born by them.

The problem I have at this point is both myself and the shop diesel formun beleive the IPR valve issue is coincidental and that I may still have a high presure issue, but Ford spent 2 days and can't repeat the problem and all testing seems ok.

Frustrating after all this effort to bullet proff this thing with no confidence I have a reliable truck. Unless others can chime in what may be overlooked, I'm all ears as I really don't want to try another mjor road trip to repeat this event.