okay, been lurking a while. I know my 7.3l really well, but picked up a 6.0l a few months ago and am starting to have an issue I could use some help with.

truck is a 2004 excursion 4x4 6.0l w/5r100 ***early 04 w/rear ICP/FPR

in the last 4k miles I have done. full engine cleaning coolant passages etc.
NEW...
two batteries, dgas bottle and cap, ppe oil cooler, remote coolant filter, afe blade runner egr cooler, new egr (factory ford) final charge nitrate free coolant, turbo cleaning, drain tube, seals, intake gaskets, oil/fuel filters, etc. truck has been running great but recently (twice now) going up steep hills to get on the freeway the truck feels like its in limp mode. rpms are up, its boosting 24psi on edge monitor, truck has no programmer, I will attach pic of the monitor when the truck is acting up. i can usually just hit the gas and within a few seconds boost this thing over 25 psi fast, but its limiting out at 24 and it feels like its not getting into the engine. it has all new intercooler boots and clamps, none are leaking. intake is sealed up. it really feels like the hot side of the turbo is spooled up but its just not boosting. are my veins sticking? its not throwing any codes, it does not feel like torque converter is slipping though those are the symptoms. it feels like the ebpv is closing or something because there is a bit of a shutter. this whole condition is intermittent. the truck has 115k miles on it. it did it today right when i got on the freeway going to town. then once i was comming home i could boost past 24 psi no problem. and it had tons of power. it almost feels like the throttle is unresponsive once it hits 24 psi when its doing it, and there is zero power, like its in limp mode, except no CEL or anything, no stored codes or pending. I should also add there is zero smoke of any kind on start up, idle, during driving, or at any time. start up is normal for a truck with early FICM.

gauges are as follows; top left coolant temp left middle oil temp left bottom ICP pressure top right IPR duty cycle right center batt voltage right bottom ebp psi center top FICM voltage, center center boost, center bottom gear/lock (shows 4th gear unlocked)

 

tomorrow I will clean the ebp sensor/tube, when I bought it a few months ago I borrowed a laptop with autoenginuity and did full buzz test, and basic key one engine running diagnostic and all was good. now that I have two powerstrokes i need to sack up and buy auto enginuity

 

Getting the codes read is a high priority.

Did you ever see a boost value over 28 psi? Could you clarify "within a few seconds boost this thing over 25 psi fast, but its limiting out at 24"? Verify that the MAP sensor hose is not plugged up. You don't have an ebpv.

What are MAP, EBP, and Baro readings at KOEO?

Is the EGR valve new or old? OEM or aftermarket? Intake clean under the EGR valve? What transmission fluid temp are you running during these conditions?

Coolant temps (and consequently the oil temps) look high to me for when you described the readings were taken. What thermostat are you running? A/C condenser and radiator fins clear? Pretty high HPOP pressure also.

Not a big fan of ppe (high flow) oil coolers:
PPE oil cooler failure after 4 months - Ford Powerstroke Diesel Forum

Not sure if you did, but I highly recommend staying w/ OEM sensors.

 

thanks for your response. any more input appreciated

 

I was still wondering about your coolant temperatures and wondering if dirt and bugs might be blocking air flow across the radiator - which the A/C condenser is situated in front of.

I don't do hills much so I can't comment from experience, just that it clearly isn't right to have to floor it to keep a 50 mph speed on that grade.

Something is limiting your power and I was wondering if it is a temperature (the PCM defuels on several temperature parameters). You might also have restricted air flow or even a plugged CAT, but I would think you would see that consistently.

Maybe post the boost, EBP, and VGT % duty cycle numbers before and after it reduces the power.

 

here is a snapshot of koeo after we got home from a 15 mile drive. truck did it twice during this drive. right at the beginning and then again towards the end. Sure is wierd, because It feels like tranny slip, but I would think I could boost like normal even with tranny slip, so something is limiting it/defueling. may just go take it to local shop. Im tired of effing with cars.

Note that I did change some of the gauges. while driving I am seeing 14psi average and 25+ under heavy acceleration on the MAP. I do not have the ability to monitor VGT duty cycle

 

one time i was driving a ford work truck with a 460 in it, going up a hill somehow, i dunno if a mechanic left it or it blew up on the road, but all the sudden lost all power, would rev out but no power. pull over, and find a rag stuck in the air inlet for the intake. pull it out and good to go. feels exactly the same. this thing is boosting and and all, its gotta be turbo veins. i will have my friend hook up auto enginuity and cycle the vgt. if it checks out, then that turbo has to come out again for a cleaning. even if its only been 4k miles. I am starting to believe the "reputable" local shop I bought this truck from may have fibbed a little on their build sheet.

 

As long as your gauges were set up correctly, the MAP, EBP and Baro should all read the same (within .5 psi anyway) at KOEO. If you EBP is set up for psia (absolute), it should be at 13.3 (+/-), not 0.

If you have an EGR throttle plate, I would remove it.

The temps look ok in that snapshot.

 

Under the conditions shown your boost should be in the mid 20's at least, in the bottom photo it is only showing 18#'s of boost. After checking the MAP hose and nipple and EBP sensor tube and making sure they are clear and in good condition, I would as suggested remove the EGR throttle plate and see if it is any better. It is possible to have an exhaust leak at the uppipe bellows that will have a profound effect on boost.

 

just checked map and nipple good. gonna pull ebp tube and sensor now. is the 7.3l ebp sensor the same? I could swap that in from my f350 to test?

 

The EBP sensor should be the same just check the pigtail. I think the 05-07 they changed the pigtail.

 

4C3Z-9J460-A is the EBP for the 1997 to early 2004 ebp as FiznUKa said (not the OBS 97 though)

 

just pulled the ebp tube and sensor. tube looks freshly cleaned. sensor was pretty clean

 

truck does have a throttle plate. I will get some gaskets and pull that apart next. would it be a bad idea to pull the batteries to reset?

 

This question is for Bismic isn't the EBP sensor not used in the programming I thought it was inferred.