You sure its not the feed line? The return line is a 3/4" tube that just drains straight back into the block.

 

Pittsburgh - 05Hd , Sorry I did not get your PM tried to send you one could not. Rod I do not know how to pass email address or phone num on this site wuold like to talk straight to anyone who has something. The last post may have something.

 

This what the mechanic who works there said. They test the returned turbo, it checks out ok everytime they use their return line. Fails when they use the Ford return line.

 

A slight correct to the turbo failure/oil return line. Well Ford finally did it and replaced my line after my turbo failed the second time. The smaller dia. line caused oil to stay in the piston actuator when it became gummed up. This would create a suction and prevent the VGT from working correctly. The fix: clean the turbo and change the line. Worked!

 

I have two 04 6.0

One is a F350 drw, cc, chassi cab with 60,000 miles on it. Its on its third turbo, I lost count of how many times they changed those blue joint connecters on the inter-cooler lines and had the hood painted twice because the hoses blew off twice and dented the hood. This truck gets about 11-12.5 mpg empty and 8-10mpg loaded. I hual hay and tractors mostly and it doesn't matter if I have 6,000lbs on the bed or I am hooked on to my tanduem dual gooseneck with a load of round bales it gets 8-10mpg. I have had to have the egr replaced and my bed pan plate started leaking at about 50,000 so they had to pull my motor to fix that.

The other is a F350 srw, cc with 71,000 miles and its on its second turbo. It never blew any hoses or egr's but it started making what they called the turkey call when you would let out on the throttle. I don't mean from WOT to nothing I mean like you just pulled a small incline and you back out a little to let it shift up. Oh and I just had to have the rear main replaced about two weeks ago. This truck gets pretty good mileage compared to my other truck. Yes it does have 3.73 gear verses 4.10's in my dually. This truck is a style side were as my chassi cab has a 9ft.flatbed with skirts and tool boxes on the sides that are full of straps and a bunch of crap. I also have a 12000 warn winch on the front of the dually also.

I am running straight 3.5 inch pipe on the dually and the srw is completely stock. I think the dually picked up some power and maybe a little better fuel economy after the exhaust mods but not enough to make me do the same to the other truck. Although I love to hear that turbo.

 

I had 6 turbo failures in 16000 mi They finally changed hose. The Ford hose would get hot and collapse. Have not blowed turbo since, but coolers a few. Undone the egr valve hope this works. 2004 model still only 38000 miles. Ford extened the warranty after court. Need to some how get the truck to preform. Found some info.
Still only 8mpg. Nothing moves that, no matter how loaded or how you drive. Stays the same. Do not want to give anyone this problem. rodsignandneon@msn.com

 

Sounds like you do not drive it enough with this milage. The truck needs to be driven to keep the vanes in the turbo from sticking. If they sit to long it will rust and cause them to stick.

The egr cooler/oil cooler problems is from casting sand in the engine from when they built them. This sand works loose and plugs the oil cooler which in turn takes out the egr cooler. A coolant filter is recommended to keep this from happening. http://www.dieselsite.com/index.asp?...ROD&ProdID=324 this is a great product for filtering your trucks coolant.

 

I will try coolant filter . As I have a 2003 to pull trailer with and it seems to build egt too fast. Has slowed down since removing converter. Alsohave diconnected egr valve. This truck would have two to three hundred thousand on it by now. It just tears up too much and we can not get the millage on it. I have found out dirty fuel is a culprit to turbo and you really have to wind it out to keep vanes from building up and sticking. Would change tailpipes but they say they do not want me to do anything that would kill warranty. No head gasket problems yet but am looking for that to happen too. This trick has a sign crane on it so stays loaded all time. Had old 7.3 on 89 350 with same boom on it ran for 750000 or more no problems. This is 550 and should do better.

 

Thread, BACK from the dead!

There are no glow plugs in a Cummins. They have an intake air pre-heating grid. They usually work EXTREMELY well. My Cummins will start with a bump of the starter. My other diesels don't start nearly as fast.

To be fair the direct injection gives it an advantage over my two IDIs.
My two PSs are obviously computer controlled and I understand the cam position sensor has to have the engine make at least one complete revolution before it will start.

If I end uop with the '04 6.0L I'm looking at it will be getting the updated return line.