Ok after repairs on pic attached, 2005 excursion LE turbo diesel started hesitating when accelerating then big black ***** of smoke, strong smell etc and been in twice since repairs they found after I took it in for a check engine light that came on twice and left.

The truck is now miserable to drive and never was before and took it in twice after dropping 4k in March and they "can't duplicate" what I go through every time I drive the truck. Granted it's more noticeable getting on freeway and having to accelerate more frequently but the smell is still the same.

My husband is gone 3 weeks a month so I have to deal with this crap so based on symptoms after repair not present before looking for another answer to suggest as I have a 3500 mile drive coming up and know my girl will struggle on inclines and not a fan of breaking down lol

 

Could be lots of things....

the black smoke on a stock truck I would look at intake restriction...air filter?

 

That was all addressed and evaluated. There is something building up, but before we took her in that was based on the smell and check engine light that came on once but went away. . After all that and I had new disturbing issues took her for 2 days and they couldn't get the problem to duplicate. Clean bill of health.

Two days ago not only did it hesitate on a full tank of fuel, she shook for 2 seconds when we had to accelerate after traffic was backed up and proceeded to go. Turbo is pretty much the best kick that yellow lights *** but I can't engage in that zoom rush because of feeling it will stall or worse. Everything looks normal but it's not. Maybe I just need hubby to buy my charger lol but I love our girl and am over dropping several grand to operate on her and taking it in getting it back with no problems but then she's performing like the little engine that could, but cany now lol

 

From the start your description sounds like an EGR valve that is hanging up. Even if there are no EGR valve related codes and check engine light, the valve can still be sticking causing performance issues. In looking at your invoice it states that the technician "cleaned intake manifold and EGR valve" which I am sure was done however, being exposed to coolant, carbon and its age the valve is suspect. Incorrect cleaning can also damage the valve which is why Ford no longer endorses the practice. I have seen this many times in the past where an EGR valve looks clean and reusable but the damage/contamination is internal. If an EGR cooler leaks enough to allow the vehicle to be driven for a while before the failure is noticed, the steam created often cleans the EGR valve almost completely - this is where and how I can see many techs and do-it-yourselfers think that the valve is in good shape. Most of the time, I will include a new remanufactured EGR valve in my quote when diagnosing EGR cooler failures. There is a static test that can be performed using an IDS in the shop and a good tech can make a data recording on a road test and decipher what is causing your drivability concern. And, for those of you who think things through and are inquisitive, an EGR valve problem can be intermittent in nature. My bet, as stated is the EGR valve based on your recent repairs but it could be something else... Keep us posted!

In proof reading this post I noticed something else. There is no mention of inspecting and cleaning or repairing of the turbocharger. Any technician who has a 6.0L turbocharger off of the engine and sitting on the workbench is remiss if he does not take a few minutes to crack it open to inspect it and service it as needed. Remember that these turbochargers rust and seize, the unison rings can wear and when exposed to coolant can gum up and stick as well. Here again I will always include this in an EGR cooler repair. Most of the time a good cleaning is all that is required.

 

Have to agree with Keith. Back smoke indicates not enough air through the turbo but if this happens under acceleration, bucks & jerks, EGR valve is stuck. What smell are you experiencing, exhaust fumes? If so the turbo Y pipe is cracked or not installed correctly.

 

Thanks for your response kinda same thought train and to leave it all day and nothing is wrong has been frustrating. There was no mention of turbocharger, think it was not a factor initially, and I assumed that with the performance complaint after EGR repairs if it was not checked at that time it would have been checked but I did not get a report of the last visit where nothing was wrong, couldn't duplicate etc. (initial complaint no issues with performance at all, just the check engine light that came and went and a strong exhaust smell) another note there was another page and repair at the same time was the tensioner/pulley.

Am sure within the next week or so I'll have to take it back in and hopefully they will find the issue. The not able to duplicate was bs. It's not a new truck, she's complicated but very well maintained with a 4" + stack of invoices for maintenance and repairs at the same dealership for years. The dealership has always been very good to us and service always A+ and no complaints. I did find out well after the repair that prior to the repairs they contacted my husband initially with the quote and such and he also gave the authorization but had some issues with how that conversation was going so demanded to soeak directly with the mechanic which he did and requested old parts after repairs. I never got them but did not know then that was discussed.

As for the smell I'm a woman so it stinks and is a chemically smell lol. I also don't "appreciate" 7.1 or 11.1 surround sound with anything more than its just noise and loud. That's all it is to me lol

 

I am not necessarily pointing toward the turbo as the problem but I wanted to mention it. The EGR valve will definitely cause your symptoms as well as the odor. These engines can produce some stinky exhaust when not running right.

 

Keeping fingers crossed. Hubby took it in before he left Thurs and talked to the mechanic who did the work and I brought it back Friday morning and they hooked up some sort of device like a heart monitor that records the "issues" as they happen in 30 second intervals when I push a button..I recorded the 4 max times over the weekend so will take it in tomorrow morning and leave it for the day. It does seem like after husband going in that issue is the egr so will see what happens.

 

Ahhh. The Customer Flight Recorder or CFR - one of my favorite tools!

 

Thanks K!

I knew that they had things for planes, trains and hearts but not residential vehicles lol. I hope I was able to get the issues recorded properly. I'll go over in the morning and drop her off for her play date..

I know a lot of places get grief from customers men and women alike who are hit with vehicle issues other than the usual oil changes, brakes and tire replacements etc..I've personally dealt with our elder truck and the semi annual and anally routine maintenance for the last 4 years, my husband a few years prior and the dealership has always been very good to us..only in the last couple years have there been any real deep pocket issues and only now have we experienced a negative performance issues after a repair...we did have the same service rep for 5+ years and he left to go to "Chevy" over a year ago so that was a bummer but slowly have since began bonding with the new "insert new G name here" but the level of service is still the same regardless and even now not negative.

Of course that's today, if we are forced to drop another 4k this week I prolly won't be quite as complimentary but am a realist and know that whether they need 2 days or 2 weeks to get her fixed, or us to cool down with the cost of repairs, they will have a loaner ready lol I am confident it's nothing more than what you have stated and that has helped...

I'll post the results as soon as I get them. Thanks to all again for the input...

 

Am sure if you've seen one you seen them all but I really liked the stick part. Only 4 shots but wouldn't it be cool if you hit that button and it was a turbo button? ��

 

Don't have technician notes or invoice yet but after they checked what was recorded, which they said was really good, they did replace the egr valve based on recordings. So thankfully that little tool was used. It seemed like they were surprised (one recording felt like I was going to lose power lol) because they said they would not have been able to find it without them.

They told me to drive it til end of week to make sure she's running good and then will settle bill. So far so good, haven't driven much yet but those feels and sounds when you are familiar and one with your vehicle feel less "off" now. I noticed off the bat a difference in the pedal and how it felt and feels and sounds when accelerating. Haven't tested the yellow light sprint, took it easy...

 

Good news!