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6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Abnormal PowerMax noise

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Old Sep 13, 2015 | 04:07 PM
  #46  
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New Y pipe/up pipe is on, turbo is back in place and clamps are back on tight. Now I'm just waiting out the rain so I can finish up all the odds and ends pipes, hoses and sensor plugs.

The old Ypipe doesn't show any signs of failure but I did find one possible culprit in the copper gasket to the EGR up pipe. In between the two layers of copper plates I could see on one side a layer of soot. We'll see during the test drive this evening.





Old vs. new





I think this may be the true culprit to the noise - some soot on one side towards the bolt. I cleaned it up and after torquing everything up this should no longer be an issue.
 
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Old Sep 13, 2015 | 05:37 PM
  #47  
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That looks like it might be the cause of your problem then.

You've definitely gone to great lengths to make sure that your turbo and air management system are solid.
 
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Old Sep 13, 2015 | 07:31 PM
  #48  
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A couple of tough bolts to torque on the pipe and rain made me give up for tonight. Will get back at it tomorrow night under dryer conditions.
 
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Old Sep 14, 2015 | 01:27 PM
  #49  
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Finally! It is time to conclude this thread as the problem is now resolved and the tea kettle noise is gone. Time to celebrate!

This bolt is a pain to get to...
 
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Old Sep 14, 2015 | 01:56 PM
  #50  
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You cleaned the turbo, added new Y-pipe and the end was a new copper gasket? Sometimes it takes a bunch or wrenching to get the real issue... nice job and way to hang in there!

Do you like the Powermax? and did you need tunes to take advantage of it?
 
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Old Sep 14, 2015 | 02:08 PM
  #51  
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Originally Posted by WatsonR
You cleaned the turbo, added new Y-pipe and the end was a new copper gasket? Sometimes it takes a bunch or wrenching to get the real issue... nice job and way to hang in there!

Do you like the Powermax? and did you need tunes to take advantage of it?
Thanks Randy! Yep, all that work and it was the copper gasket - haha.

I really like the PowerMax and run Gearhead tunes specifically adjusted for the PowerMax. A very powerful truck!
 
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Old Sep 14, 2015 | 02:15 PM
  #52  
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was the Y-pipe hard to get into and out of place? Not counting the hard to reach bolts, total time to replace the pipe? And how much extra time on bolts alone? Could you do it faster now it's been done once?
 
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Old Sep 14, 2015 | 02:28 PM
  #53  
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glad to hear you got it fixed up!
you can probably remove the turbo in 10 minutes flat now!
 
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Old Sep 14, 2015 | 02:29 PM
  #54  
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Originally Posted by WatsonR
was the Y-pipe hard to get into and out of place? Not counting the hard to reach bolts, total time to replace the pipe? And how much extra time on bolts alone? Could you do it faster now it's been done once?
Basically 6-7 hours in total spending two hours on the hard bolts alone. I could probably cut at least 2 hours out now that I have experience. Plus I have removed and reinstalled the turbo countless times it seems which in itself can be a hassle the first time around.
 
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Old Sep 14, 2015 | 02:31 PM
  #55  
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Originally Posted by evan1242
glad to hear you got it fixed up!
you can probably remove the turbo in 10 minutes flat now!
Haha - smooth as butter now. I feel pretty darn confident with the turbo removal now. Probably not 10 minutes, more like 12.
 
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Old Sep 14, 2015 | 02:45 PM
  #56  
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Originally Posted by Magnus E
Haha - smooth as butter now. I feel pretty darn confident with the turbo removal now. Probably not 10 minutes, more like 12.
yeah if you add in the once your done
 
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Old Sep 14, 2015 | 02:58 PM
  #57  
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So much for a turbo installer pro - just noticed I have to re-align one of the clamps as there is a small leak (whooshing sound) - no big deal, an easy job.
 
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Old Sep 14, 2015 | 03:01 PM
  #58  
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nah, your still a pro..
but you can loosen up the turbo then align the pipes/clamps while its loose. makes it easier.
 
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Old Sep 18, 2015 | 07:14 PM
  #59  
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My Ex only makes the right noises now. Here is video proof.

Again, thanks to everyone for helping me track down and fix it.


 
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