I have a 2004 F-450 6.0L diesel dumptruck with 16,600 miles, About a month ago while towing my 12,00lb mini excavator i heard a poping sound and then lots of black smoke and lost all power while towing on the interstate about 60mph. The tube leaving the turbo going to the intercooler blew off, i put it back on after getting off the next exit. I took it to the deraler i purchased it from, they replaced the clamp and rubber boot. exverything was fine for about three weeks then it blew off again. Took it back to the dealer and they could not get the hose to stay on, every time they tried to drive it it blew off. The replaced the intercooler saying it was restrictive and i got the truck back, on the way home the hose blew off about two blocks home. I limped it home and today it was towed in to the same dealer again. This is the third time it has been to the dealer, they say they do not know what is wrong and have to talk with engineers from ford. I not sure what to do, dose it fall under the lemon law since it has been back the third time for the same problem? I am loosing thousands a day, I run my own business and i need my dume truck to move equipment and haul material (Dirt, sand,stone). They said it would be days and they will not give me a loaner. I am going to have to rent a dump truck, is their any way to get ford to pay for it. I paid about $46,000 for the truck and the dealer is not helping me at all. Any hel would be greatly appreciated

 

Right off the bat, My money would be on your turbo is overboosting due to stuck/slow vanes. Your dealer will probably want to get some kind of proof of this. Ask them to hook up the "vdr". Thats the vehicle data recorder. It records information prior to and after the incident. Have them program it with-mgp, map, rpm, and maf. What needs to be done, is either replacing your turbo,or at least cleaning it.

 

I don't know if your '04 has the plastic tube or not, but there was an upgrade being done on '04s to replace the tube with an aluminum one, which was supposed to stop that problem of the hose blowing off -- my friend had his '04 done under that program and no problems since...

Hopefully your service dept. will find that if it applies to your series motor...

Maybe one of the techs here can give you the specifics to take back to your service dept.

 

First thing you have to do is replace your dealer!!! They obviously do not have a diesel mech!

 

Found this -- I think it's in a link off the 6.0 technical thread (I saved a copy on my PC tho...), hope it helps:

Customer Satisfaction Program 05B29, 2004 F-SuperDuty and Excursion:
Trucks built between 12-15-03 and 3-31-04 with the plastic cold side intercooler tube with worm gear clamps (tubes marked "9 NM") are being recalled for replacement of the cold side tube. The replacement is an aluminized steel tube with silicone hose ends and T-bolt clamps, part number 6C3Z-6C640-AA. This recall will be in effect until 7-31-06, regardless of mileage.
2004/05 Trucks:
The recall does not apply to trucks built after 3-31-04 with the plastic tube and T-bolt clamps (marked "12 NM"). These trucks are covered by TSB #05-22-3. If the plastic duct on these trucks blows off, and the tube is undamaged, first reinstall the plastic along with a reinforcing ring. Position the ring over the duct and under the clamp, with the gap opposite the bolt on the clamp. If the clamp is broken or missing, replace it with p/n 1C3Z-6K786-BA. Clean all parts before reassmbly. If the duct continues to blow off or was damaged, replace it with hose and tube assembly 6C3Z-6C640-AA.

 

Truck already had aluminum tubes... Stopped by the dealer today,mechanic said no one including ford tech. line could help him, he drilled a hole in the pipe comming out of the turbo and drove the truck with a mechanical gauge on the pipe while recording the boost pressure on the scaner. he said he got 35psi on the pipe leaving the turbo and about 28psi to the engine..Not sure where the 7psi went maybe loss across the intercooler. He dose not know and no one knew what the max pressure the tube could have and why their is a 7psi difference between the tube pressure and the intake pressure recorded off of the computer. He also removed the valve in the intake that restricks the flow for the egr valve. with the butterfly valve removed he still got the same numbers, guess it was not the valve getting stuck. Ford tech. authorized them to replace the tube, rubber boot, clamps, and turbo. No one has an answer, they think that the lip on the turbo is not big enough to hold the rubber boot on, (possaibly due to bad machining) they came up with this because the hose dose not blow off on any one of the other four connections. He said i would have it back tonight, hope everything is fixed

 

The difference in boost readings is due to restrictions in the intercooler, tubing, etc. It is normal to loose a few psi of boost between the turbo and the intake.

The boost is too high. It should be around 22-24 psi stock. Your dealer should know this. The new turbo should fix your problem.

 

I work on the 6.0's alot and from my experience the most common cause for
pipes blowing off is not cleaning them properly before they are reinstalled they have to be clean, really clean and the rubber will be sticky to the touch
so it will stick, oh and for the boost most will be around 27-29 psi at wot when it's in 4th gear and is in it for a while, that is on all the f series that I have driven.

-
Ryan