The truck is a '03 F-350 4x4 CC Dually. Stright Pipe, SCMP on Econmy mode..

The Problem became apparant the day before yesterday when Pulling about 3000lbs... Off the bat it was fine, But about 40mi into the trip i noticed a minor loss in Power, When i let off the gas in a turn i let it idel down and when i hit the gas i noticed that it was Extremely loud at lower RPM's... Normally it would Whistly Very lout untill 2100RPM then it would sound like a Big Block.. But at that point it sounded like a Stright piped 454 at idle and throughout the RPM Range..

I pulled into the Hotel we were staying at about 40mi later to rest for a moment before i got to the Off Road park to do some riding.. I noticed it sounded just like a Stright piped Cummins. So i shut her down for about 20min, Then hit the road for the remander of the trip.. I hammerd it to merge onto the highway and it wouldnt move... It was reving out as if it was moving fast but topped out at about 40mph.. the Boost gague was jumping and the truck was Sputtering every time the gague flutterd.. I thought i might have a Hole in a Boost tube coupler or something that made me lose boost pressure..

I pulled over and took a gander under the hood, I noticed that at idel out of gear when i punched the gas it sounded normal but there was a Loud poping and or sucking noise coming from the engine compartment right around the airbox.. Let the truck rest for awhile drove to the park w/o power... On the way back from the park it started to jump and sputter again, Sounding like crap... So i pulled over and unpluged the EGR, The rpm's jumped up, The truck wasnt loud anymore and sounded Perfect.. No noise, Just like new..

Well about 40 mi into the trip on the way home it started getting loud again, Lost power, no popping noise like before.. If i were to punch the throttle it would stay at the same rpm for about 20sec before it would jump up in RPM's..

Just felt like crap but got me home.. Shut it off, Started it up with the EGR plugged in and it started popping, Sputtering... The Boost gague would jump around very bad once the turbo kicked in at 1800rpm... and pop when let off... So i unplugged the EGR again and it runs fine, I put about 40 mi sence then running around town w/o a load. No problems

So if its the EGR then why would the truck run like crap w/o it plugged in but only on long hauls, But dosnt hardly run at all with it plugged in?

Maby Internal, Lost compressing in one or more cylinders? Head gasket?

Sorry for the long post, I just need to try to figure it out..

Thanks

 

Yes. Sounds like your EGR is staying open when it is plugged in. EGR is supposed to be closed when manifold pressure is higher than exhaust back pressure. Welcome to the crappy EGR club.

 

yes to the EGR valve going bad. On my 04 had this problem. They came out with a different design EGR valve. 2 months and no problems yet with the new design.

 

Sounds good to me.... But is there a reason that when unplugged it still acts weird after time??

When unplugged shouldnt that get rid of the problem if the EGR is bad? When people unplug the EGR on this board they dont report any problems...

So i dont get raped, Is the EGR something i can replace myself and if so high is the Part from Ford?

 

It may be stuck in the open position and never closing.

In this instance, it will need to be cleaned or replaced before you would attain any benefit by disabling the EGR valve.

 

So pretty much, With it plugged in it will Constantly Screw with my motor... But with it unplugged it will Screw with my motor in a Different way ..

Im glad to hear that... The motor does have 135,000mi on it... Wonder if this is the original EGT....

 

In looking at the work order they replaced an EBP sensor 4c3z*9j460*a
and egr valve 4cz*9f452*a

 

Hey Big Red, When they replaced the EBP did you notice Quicker warm up time at first start?

I was thinking about taking it in for a New EBP Anyway because it takes so long to warm up in the morning...

 

Haven't noticed it. But it sounds like a good idea. This might help with carbon on the EGR

 

Ok BTT...

Problem was not solved by replacing the EGR $375 bucks...Runs fine when unplugged but not with a Load on it.. Runs like crap constantly when plugged in. I bought a Factory Replacement turbo after taking it to a Local dealer. They said it was the VV or something. Then the second place i took it said the same..

Now im Getting ready to install it, But after reading other's posts, Some have the same Problems i am having and they didnt Buy a new turbo... Im looking for any possabilitys in order to save the money becasue i can still return the turbo..

Would it be the EBP? Would that be something that effects the running of the turbo with the egr unplugged...