I have a 2003 and had various problems and I just had the intercooler hose couple blow off again. I have blown the top blue hose in two, blown the inter cooler apart, blown the hoses off twice. (done the clean and replace) I have experienced this only when towing and it is pretty scary when this does happen. They have replaced the turbo and egr. Now they are telling me that there is a newer turbo that may help and that the latest flash will also help. The newer intercooler hoses are also a possibility. I used to have the Edge product on it but I sold it over two years ago and most of the problems are since then.

List of problems to date
EGR replaced
ICP sensor replaced
Wire chaffing
5-6 reflashes (wich seem to hurt more than help)
steering gear box replaced
three oil leaks
Turbo replaced
intercooler hose replaced
intercooler replaced

These are all I can remember
I have 36200 miles on it so far
Stock except for exhaust, lift and larger tires.


I am concerned as to what to do. Keep with the repairs, try a buy back or just trade it in. Does any one have any information on the 5-6000$ allowance they were doing for us 03-04 owners?
Help

Nov 2002 build date

Armon'e

 

Have not been told about a 5-6000$ allowance when I complained to dealer about my '03 problems. Ford rep. offered me $1000 toward purchase of new truck. Told him what he could do with the $1k.

 

Yeah I get your drift. I have nearly been in 3 accidents while pulling my 10,000 lb toyhauler and having the intercooler problems. I would like to know what they would say about a lawsuite involving a wreck that occured because of their inablility to solve these problems. It sucks to be a $40,000 test driver.
I was told that the ones that were having problems were mailed a letter outlining the $5-6000 rebate. I never saw one.

 

I believe that offer expired on May 31, 2006... It was specifically directed to original owners of 03/04 MY 6.0 psd. FWIW You should be able to get 9-12k off sticker on a new 06 psd even without the "loyalty" incentive-

 

My next question is "Are the 06 models any better thatn the 03-04" I know they have a lot of the bugs worked out but I still hear of problems with this setup. I guess what I'm getting at is with mine mostly paid for should I wait and see how the 08 are and if they are as good as they promise. I feel that with my warranty running out dec of 07 that would give me a full year of feedback on the new motor. I think that Ford owes all of us with these problems a big appology. I have been a loyal FORD owner for the last 20 years "since my first Truck" and Ford now has me actually considering another make. I can't believe I just said it myself. I currently have 3 Ford trucks a 93 f150 4x4 that has 170,000 miles and runs like a top a 01 F150 SuperCrew with 66,000 and no problems then there is this one with 36,000 and in the shop after every towing trip.

Very frustrated.
Armon'e

 

I would wait to see what happens. Who knows, they might come back with a big "stick with Ford" rebate for 6.0 owners again.

In addition, I think many of us are somewhat apprehensive regarding real world effects that the new ULSD will have on old and new diesel designs.

 

any more, I see corporations outsourceing components to a degree that no one knows who built what. Ford with international, garrett turbos,who knows who makes injectors and solenoids. Gm is just as bad with izuzu, toyota,suzuki, and others. The training is mandatory any more to even start to diagnose these complicated vehicles. Sometimes even the training leaves a lot to be desired. When I first got my diesel certification, I was just as much in the dark after the training as I was before. Was there dissatisfied customers---probably, The object is to learn from the mistakes. Some techs have a more difficult time than others learning. Tool room organization, accessability to on line updates of reference material, of course, tech competency is right there with customer attitude. Patience is the key, it might just take time. Its not like working on the old 67 chevvy any more.

 

Vloney: I understand your point. The problem will be that with the limited miles I put on the vehicle (roughly 8000 miles per year) I will be out of warranty before I get all of the problems taken care of. All of my problems are when towing and I only tow two to three times per year and its around 75% of the time that I tow that I have a problem. By the way thatnk you for your replies... all of you!!!!!!!!

 

tell them if they can't keep the Ford intercooler setup together then they should replace it with a Banks unit at no charge to you. lol

 

theres even some problems that show because of low use (yeah, I know, you cant win)

 

Believe it or not that is what they told me when I took it in there the last time. "you need to drive it more" how many of these 6.0's would they have sold if they would have told us the truth

must be driven enough but not too much to cause problems
we will reprogram the truck when we want and you will loose perfomance
we will take you enginge hold back away in 4th and 5th gear
we will take one of the biggest selling points away "the quite pilot injection"
we will program it so it gets les mpg than the 7.3
we will make you drive an unsafe vehicle
you will have engine oil leaks as soon as 2000 miles
we will phase the engine out in 3 years
we will loose market share to the other makes becaus of the above
your $40000 TRUCK will be worth less than others at trade in because of these things


this is just to get started.

Armon'e

 

Well they are replacing the Turbo one more time and the intercooler hoses & clamps. They can't find the engine leak so they may have to pull the engine. I now also have a front axle seal leaking.


Did I mention that there is only 36,000 miles on the truck.


I must say the guys at the service department say they are as frustrated as I am.

No that is not true there is no possible way they are as frustrated as I am; they are not the ones paying for all of this frustration!!!!!!!!!!!!!!!!!

 

again, all they need to do is check out the on line updates. look at my post"repeat turbo failures"

 

Vloney: I have read your post: I highly doubt that it is a programming issue. I have been told that because my truck is not a daily driver that the turbo will "rust" causing the vanes to stick and over boost or under boost. The new turbo as you know has the "reverse cut" vanes to hlp keep it from sticking.

If I get your implication correctly you are telling me that Ford has this figured out. I totaly dissagree. They have not fixed one thing that my truck has had wrong yet. Other than putting a bandage on it or reprogamming it so that the problem is not as big an issue.

Frod has reprogrammed this truck completely away from the "truck" that I purchased in Dec 2002. You being a tech should agree with that!!


If you have it figured out please let the rest of the techs know!!!

I do appreciate all of your information.

 

the new turbos have a relief cut into the housing so the vanes are no longer touching the housing allowing them to rust to it. The reflash adds software that cycles the pid(vgtdc) from 0% to 85% whenever it sees slow, or no moving vanes in an attempt to break them free. It also adds the pid (vgtlrn) to show whether or not the pcm has" learned " the new turbo operating strategy. Incorrect reprogramming procedures have been made in the past that create new driveability problems. The special service message is an attempt to help the tech to verify correct procedures in the reflash.