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I have the same problem on my '05 6L after about 95K miles and two or three belts. I was also having an overheating/fan short cycling problem with squeal every time the fan started or stopped - sounds like a bearing. Ford said the thermostat and fan clutch needed replaced. Neither one fixed either problem. Next they said the tensioner needed replaced although they didn't have the tool to test the belt tension. They replaced the tensioner and it still squeals mainly with fan on and engine in 2600 - 3000 range (warm day with a load - trailer). BulletProof suggested light sand paper on the fan pulley - haven't tried that yet. BulletProof did determine that the high pressure oil system had a leak. They tested the regulator and high pressure pump - both okay. They found a leaking injector (fourth one so far). They fixed that and the overheating problem and fan short cycling problems were cured.
Wgb, you had bulletproof test you truck? I'm located in Athens, Georgia, and other than dealer don't know of a good diesel shop that I trust. How did they find the leakin injector?
Yes, BulletProof tested my truck (I am in Arizona). Their home office is in Georgia, so there should be a dealer back there. Go to their site and call them - they have several shops authorized to do their installs/work. While testing for my overheating problem - they found nothing wrong with the cooling system - they noticed that for the engine RPM, the high pressure pump psi was low, so they started looking for a leak in the high pressure fuel system. The checked the easy things first - regulator and pump - when those were good they had to go into the valve covers and found a bad o-ring on one of the injectors. They replaced that injector and the cooling system problem - fan short cycling - was gone. Ford didn't even test for a fuel pressure problem. As I said, the squeal is still there at higher RPM with a load, but since the fan doesn't short cycle all the time it is not as bad as it was. When I get time, I will run some sandpaper over the fan pulley to see if that eliminates the squeal. Besides the fan clutch and tensioner pulley, one of the idler pulleys has also been replaced, but the squeal is still there.
Well, the squeak was getting to me and my alternator went out. Thought I'd replace the alternator and smooth idler that right below it since bearing were a little loose. Got the smooth idler off, what a pain BTW, and replaced it with a new from Gates, got the alternator back on and thought how nice it will be to not hear the chirp anymore. Started the truck up and it is squealing now not chirping. So I took the alternator back off and took idler half way back off to make sure it set on bolt right, it was, and tightened it back up. still squealing… This belt squeal and chirping (now squealing) is about to drive me absolutely crazy.
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