I have a friend with an 04 6.0,did the EGR delete,new cam w new bearings,ARP head studs..
here is the problem, which is intermidete,truck will be running fine and then all of the sudden it will start surging,let off the throtal and go back to light throtal its okay but with good throtal it feels like the turbo is kicking in and out and back to surging..During this it smokes black and sometimes white..Ocasionally,it will stall (quit) but will fire back up...

 

Dang who did his work? Did he clean the turbo when all that work was done? When he accels hard does it ever overboost? A stuck turbo i know can cause black smoke... I see you have a 7.3 so i dont know if you know the VGT. Just somethin to try n rule out.

 

Maybe check and make sure the connection at the VGT solenoid on top of the turbo is all good....probably too simple to be true, but possible being that the turbo was out and disconnected. I had a surging/bucking issue out of nowhere and very shortly after I started having those issues my HPOP took a dump. Not saying that is his issue, just throwing out some ideas.

 

check the vacume tube that connects to the passenger side valve cover and make sure it is connected and also push on the wiring harness between the fuel and oil filters to see if it dies, mine hade a bad wiring harness that when pushed there it would kill the engine an also the connector below the turbo the wires were melted together inside of the ribbed protected tubing.

 

my 6.0 surge and stall was the MAP and connection to egr cooler,you have egr deleat so I dont know about the map try cleaning , ICP and connector ford sells a pig tail that fixed the issue.

 

thanks for the replys..i will let him know and post back what he finds..