Hello,
Long time lurker and first time poster. This forum has been a tremendous help to me ever since I started looking for a diesel truck. Thanks to everyone!
Quick history:
I found a truck 2 years ago with a egr going bad. 2005 F250 with 225k miles. Bought it and took it straight to a mechanic and had it torn down and fixed. Deleted, head studs, head gaskets, injectors, fuel pump, water pump, ficm, blue spring mod, radiator, hpop, etc. I may be forgetting some stuff. Everything is stock no tunes etc. Ran the truck for 2 years with no problems. I am using a dashboss to monitor. I use Schaeffers 5w-40 full synthetic, Motorcraft filters, I change the oil every 5k and fuel filter every 10k. I run Opti-Lube in every tank of diesel.
Quick side note to give back to everyone: It had an intermittent hard start where sometimes I had to crank it multiple times before it would start. Didnt matter if it was hot, cold, nothing was a pattern. Mechanic had no ideas. Searched the forums and couldnt find any answers. Finally replaced the starter with a 6.4 a while back and have had no problems since. Maybe this will help someone.

Back on topic-
4 weeks ago I was towing about 9k lbs and truck suddenly got hot. ECT got up to 255, EOT to 230. Pulled off the interstate quick as I could but did puke a little bit of coolant from the degas bottle. Had my dad bring me some coolant and crippled home driving slow and keeping temps below 220.
I replaced the thermostat and water pump and took it for a drive. The truck was no longer overheating but it was running 10 degrees hotter than normal. And it had poor acceleration and power and the turbo was spooling up but only providing boost intermittently. It was shifting hard at times especially at higher rpm’s. Drove the truck like this for about a week and did research and finally took it back to the mechanic who did the work initially. He ran diagnostics and told me it could be the turbo vgt pigtail wiring since it looked a little rough or it could be the turbo was bad. There were some codes related to turbo boost but I didnt get the actual numbers from him. I replaced the wiring and that didnt change anything. Turbo was getting worse and eventually quit working. I decided I would rather replace the turbo since it was so old and the mechanic quoted me $500 labor to replace it. At this point I am questioning his expertise since I know some things about the turbo functions that he didnt know and I don’t know much! And the guy who worked for him and actually did the work before no longer works for him so now I am getting concerned especially when he kind of guesses what the cost will be and acts unsure what it will take to replace the turbo.
So I ordered a KC stage 1 and the updated oil fill and drain pipes and when it came in I watched some videos and changed it out. Far as I can tell everything went smooth and afterward I started the truck right up. It started fine but then idled rough. I let it idle for a while and took it for a drive. It continued to get worse and by now the whole truck is shaking badly and has no power. The turbo seems to be working, its building boost and sounds fine. The truck barely made it up a hill and I parked it and it sat for about 3 hours. I went to start it and it cranked and cranked and sounded horrible but eventually started. It was running extremely rough and barely went a block when it died and wouldn’t start anymore.
The next day I picked up an SCT so I could read codes and pulled these codes (the mechanic did not clear codes when he ran diagnostics a week or so before):P0046 turbo

P0069 map sensor

P0266 cylinder 2 contribution

P0299 turbo underboost

P0403 egr

P0405 egr

P0528 fan clutch

P2138 pedal position sensor

P2139 throttle/pedal position sensor

P2614 cam sensor

P2617 crank

I cleared the codes and cranked it some and it threw these codes:

P0237 turbo boost sensor a circuit low

P0470 exhaust pressure sensor a circuit

Monitoring showed ficm was good and in sync, ipr, icp, and everything else I could find that might be related all showed good.

I replaced the Map sensor and cranked some more and no more codes came up. Gave up and had it towed to the mechanic.

He ran some diagnostics and told me he pulled the following codes:
P0266 cylinder 2 contribution
P0281 cylinder 7 contribution
P0470 exhaust pressure sensor a circuit

I know the wiring harness is rough is several places so I asked him about it. He said “codes say injectors not electric fault”.

I don’t know what to think. I’m upset my injectors have only lasted 25k miles and I have done everything I know to do to keep them going.
But I keep thinking about how the truck ran great and had no issues whatsoever and suddenly cratered on me. Its not blowing smoke and had no missing or anything, just turbo problems after it overheated and then I replace the turbo and boom its done.

Did I do something to mess something up when I replaced the turbo?
What do I need to do now? I’m not even sure what is wrong with the truck. And the mechanic is not inspiring confidence.
And how can I keep my injectors alive in the future? I cannot spend $3k every 2 years!

Thanks for any help or advice!