I need some help guys. My '03 has been having this problem on & off for several onths now. It is only apparent when towing loads over about 4,000 pounds; If I come to a stop after normal driving, then take off again, there (sometimes) will be no boost what-so-ever. This can be really interesting if trying to merge into traffic. Anyway, if I keep my foot in it, after a couple of seconds, it feels like some circuit somewhere closes, and it goes from no boost to full boost in a nano-second. The event usually triggers a code (but no light). I don't remember the code description, but it says something about "lack of boost". Anyway, the dealer has replaced my turbo and my EGR recently. But yesterday it did it again. To compound matters, I recently installed a 6 gun bundle. I really enjoy the benefits (power is awesome and I'm actually up 1mpg while running around on level 3). If anyone has any ideas as to what's causing this, I'd appreciate the help. Otherwise I guess I'll have to ****** the mod's out & take it back again.
By the way, I haven't disconnected the EGR yet because the info from the tech folder says on early '03's it won't make much of an improvement. I'm probably going to disconnect it just to see if it has any effect on this no-boost issue anyway.
Suggestions?

 

Don't rule out the possibility of the new turbo being bad. My early 03 had power loss problems only after towing for 100 miles or so. It appears the actuator in the turbo was sticking only when really hot such as after a long pull. A replacement turbo cured mine.

 

I've been fighting this problem with mine for 5000 miles. Have you tried the Exhaust Back Pressure sensor yet? Mine was replaced and it made no difference. Next they said it would be the EGR, then the turbo. Mine seems to do it worse the higher you turn the chip up. When you run it stock it hardly does it unless your pulling a load or going up a steep grade and go to shift. It's like there is no boost and the EGT's soar then all of the sudden something kicks in or changes and it boosts. I think mine has never thrown a code. Keep me updated when you get it fixed and I will do the same so you can fix your rig also.

 

PS.. When they replaced your turbo, was there a tech from ford that came and inspected your truck? I am wondering this cause if there was, I got a feeling the turbo is the next thing on mine they will replace cause the drain valve is leaking. I want to put my converter back on if a tech is coming to look at it.

 

Pan;

They checked the EBP sensor & said it was fine, then proceeded to re-program everything. Cleared the codes & said drive it a few days, bring it back & we'll re-check for codes. I did so, the same code was back, so they ordered a new turbo. No one from Ford ever came to investigate, just the tech at the dealer. I was number 90 on the back order list for a turbo. I made some noise and after a few days, a new turbo appeared. They installed it. Made no difference. Next they went ahead & replaced the EGR. Still no change. I installed the mods (somewhat against my better judgement, but did it anyway). It seemed to be better until I pulled my boat the other day, then I got the "no boost-sudden boost" deal again...
Anyway, I'm going to unplug the EGR & try it for awhile. If it still acts up, I'm going to go through the chore of removing the mods (except the exhaust) and take it back to the dealer again. I'll let you know what happens.
Thanks for your input.

 

I'll await to hear from you.