im new to this furom, i have been lurking for awhile though. i need some insight as to what is going on. i have posted this on a few ford and diesel facebook pages also.

ive got a question/problem/update. 03 f250 6.0 would a plugged intercooler cause high boost numbers? im running about 11lbs at 60 on flat ground. my fuel economy is also half of what it was. im pushing 850-1000 on the pyro at steady cruise. i know a plugged cooler would cause high egts and poor fuel economy. boots are good. turbo is good. insight says vgt is adjusting. cleaned map sensor. it agrees with the barometric pressure. replaced EBP sensor and cleaned the tube. turbo is good. i havent touched the oxygen sensor yet. could that be the cause? its cleaning up good. only smokes under heavy acceleration. no DTCs. shifts fine, sounds good. idles smooth. feels like it lacking power. have studs, egr delete, oil cooler, coolant filter, fuel pump, and one new injector 7,000 miles ago. changed fuel filter and oil 2,000 ago. about 25,000 on this air filter. air filter doesnt appear to be overly dirty, and isnt up to the first line on the restriction gauge. all fluids are good. 122,000 miles on truck. i had the mileage wrong last night. also, would the coolant filter cause said issues? i would think it would only affect the coolant and oil temp. coolant and oil temps are fine till egts climb, then they rise with it. the egts climb first. thanks in advance guys. i need help quick.

under the same conditions i am usually running 5-7 pounds of boost. stock sticks, stock turbo. it started under heavy acceleration, unloaded, with my hot tune loaded on. it made a couple "bang" sounds, followed by the turbo coughing. i got out of it and the turbo started to behave. now with this issue. switched from my performance canned sct tune back to stock. turbo behaves normal. vanes were cleaned 7,000 miles ago. any ideas whats going on? im a broke college kid in need of some quick help.

 

update. unplugged vgt solenoid. egts cooled 200 degrees. boost was back to almost normal 7-8psi. how do i tell if the solenoid is at fault?

my theory on why my insight read it was moving, was it sees the demand from the pcm to move it and tells me that. i came to that conclusion after i unplugged the solenoid and it was still showing movement on my insight.

 

Correct, VGT% in your Insight is "demanded", not actual. Watch EBT, if it doesn't change as VGT changes then the vanes aren't actually moving.

So the good news is, since you're a broke college kid and all, you can rebuild your turbo in your dorm room for:
$160 for a rebuild kit
$170 for the solenoid
$160 for a unison ring if you need it
12 point 8mm socket - $10
5-75 lbf/ft torque wrench - $115
3M pads - $20

But seriously, we can get you through it, probably for cheaper than that. The only way I know of testing the solenoid itself is to ohm it, and replace if it passes. By that point your deep enough to make sure it's not the vanes rusting down.
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