I have been having a problem with my turbo surging since December. Ford has replaced the actuator, egr valve, and the ebp sensor. I found out that each time they replace something, they reflash the truck with the latest flash. When I get the truck back, I have no surging for about two weeks and then the surging comes back.

I called my dealer this morning to set up another time for the truck to go in (the last time was 3 weeks ago). They said that Ford has issued a statement saying that the surging is "normal." They have seen numerous trucks come in or owners calling about their turbos surging, so it appears that I am not alone. I was wondering if some of the more experienced PSD guys on this site, that seem to have access to bulletins and other information, could do a little research to see if this is true?

I have a boost and pyro gauge on my truck and the boost doesn't seem to bounce up and down with the surging and my egt's don't appear to be affected either. I have heard that 4 in exhaust may fix the problem, but the dealer said that one of the trucks they serviced last week had big exhaust and it only made the problem more noticeable.

My truck has a buil date of 12/02 and I bought it in 7/03. I currently have 25,200 miles on it and as far as I know, I was up to date with my flashes as of October 2003. I really enjoy my truck and I just wish that this one issue would be resolved. I'm interested to see what kind of feedback I get. Thanks in advance.

 

There is a December 03 flash for the 03 engines. If the boost doesn't show any fluctuation, how do you know the turbo is surging?

Here are the preliminary checks for surging:

Perform the following preliminary checks:

Confirm brakes are not dragging.
Check for oil in coolant.
Check engine oil level.
Confirm oil change within 12,070 km (7,500 miles).
Check air intake system: Air Filter Minder.
Check MAP sensor hose for holes, blockage, or disconnection.
Check EBP sensor tube for holes, blockage, or disconnection.
Check intake manifold system for leaks.
Confirm acceptable SAE oil viscosity and API rating of oil.
Check for sufficient clean fuel.
Check for air in fuel.
Check for intake restriction.
Compare loaded weight of vehicle with performance expectations.
Power monitor active.
Transmission concerns.

 

Try the instructions in the first post of the EGR disconnection thread and see if it does any good....

Not by any chance could it be a transmission issue?

 

I had the same problem from the day I bought my 04. First time I took it in they replaced the EGR, it didn't help a bit. I did a bunch of research and found somebody with the same problem. They recommended the EBP and VGT(variable geometry turbo) sensors. I took mine in and showed the mechanic what all I had found. He said he couldn't get any codes while sitting in the shop so he hooked up some computer he had and drove it down the road and saw the problem then. They replaced the EGR, EBP, and VGT and it has run fine ever since. That was about four months ago.

 

It's mainly a hearing problem. You can be going down the highway at 70 mph and when give more throttle, you can hear the turbo fluctuating, but the gauge doesn't move. I'm trying to get a TSB number and will post it when I do.

 

Everything but the VGT sensor has been replaced (at least I think it hasn't been replaced). The good news is that I don't seem to be loosing any performance because of it. The bad news is if I put 4 in. exhaust on the truck, I would hear it even more. Pretty much a bummer since I wanted to make my truck a little louder.

 

Don't know? How would the transmission affect the turbo? I'm still learning about these new 6L's. The transmission seems to shift just fine accept for the "normal" thunks like everyone else is experiencing. The funny thing is that I don't ever really notice it when I'm in tow/haul mode with my trailer behind me.

 

Sewhalen35

A buddy of mine had the same problem with his 04 superduty in jan. of this year. Ford replaced the same sensors on his as they did yours and it still did the surging. Then they told him just what they told you, "normal". Well, I let him ride in my 04 to show him what its supposed to sound like and then I road in his, and man that thing sounded like a sick pig. To make a long story short, he asked for a rep to come down and look at the truck which happened the next time he took it in for service. Here is what the rep told the mechanics, "put a new turbo on it". They did and it is totally fine now. I dunno if your dealership listens to the customer when it comes to fixing things, but if they do, I would try to get a new turbo out of them.

Just my 2 cents

 

Mine had the exact same concern. You could hear the "surge" more than you could feel it, mine moreso when cold. I had disconnected my egr to see if this made any difference, none. I then replaced the EBP sensor, no difference, I then replace the VGT sensor, NO more surge-sound, runs smooth and sounds great!!! Get them to put a VGT sensor on your truck, if this does no work I know of one where the turbo asm. was replace (just as the above post) and the problem is gone!! hc