I recently brought my 05 into the dealer for lack of power. The dealer installed a new turbo because the old one was randomly sticking. Now the truck has a surged through the entire power range. The boost surges anywhere from 1 psi off idle to 5-6 psi at full throttle. As this is going on the engine will not drop rpms but will stop, raise 20-50 rpm, stop, raise again, stop, raise again under light load. Under heavy load it becomes a ,,, well,,, very unique experience. Brought it back in and they hooked up the laptop and took it for a ride and said they can feel, hear, and see it but say everything electrically/mechanically is working properly and the turbo is doing what the pcm tells it to do. I don't buy it.

I learned a long time ago if it was fine and then you worked on it, now it doesn't work, go back to what you did last. Is there anything turbo related (sensor, valve, anything) that would cause this problem?

They seem to think it has something to do with the after market parts that are on it (green filter, 4" exhaust & spearco intercooler). I didn't buy that either. They won't do anything more till it gets back to stock form. So I'm on my own for the moment. Is there anything I can check/do narrow down the parts list that I may have to throw at it?

 

Maybe a small leak somewhere causing pressure to build and release from the turbo. The higher the pressure the worse it becomes.

 

Since you just replaced the turbo ............

VGT can be the problem if you have periodic surges
https://www.ford-trucks.com/forums/6...rge-fixed.html

Turbo oil leak can impact VGT solenoid

Also (more frequently these are issues, but may not be for you since you had the turbo work):

EBP harness, ICP harness, EGR valve

 

The surge happens about every 1-3 seconds. I just disconnected the batteries to reset the pcm and let it idle for 5 minutes. I also went to a ford fleet center and their willing to take a look at it. They said if they can't fix it noone can. They seem mod friendly so we'll see what happens. They where telling me that one of their customers runs a tuner on the max setting and always has a space 6.0 in his garage. He's gone through a couple of engines already. I think they're trying to make a point about tunings.

 

Sacu-

My 06 just had the turbo replaced for sticking as well. How many miles are on your animal out of curiosity? I had 38,000 miles on my truck, 2-3 times a year if she is lucky she will pull a 13,000lb trailer, in the summer she tows a boat on the weekends, otherwise she's a daily driver. I love my truck but I was stunned at 38,000 a new fricken turbo. I am not bashing Ford when I say this but my lb7 when I had it was at 80,000 totaly modified and not one issue. Like anything it could have been a bad batch and no ones immune it seems.

Thanks,

Pit

 

I had a similar surging problem on an '03 with 108,000 miles, but I had a P2285 code come up. I didn't have the mechanical ability to change the ICP Sensor and harness which are located at upper right rear of engine (hard to get to) and had Ford dealer replace it Dec. '06. $360 labor plus $155 parts + misc for total of $552.24. Truck has run fine ever since, and now has 130,000 miles. You might want to let local auto parts store connect and test for any error code. Auto Zone did this for free. Good Luck!!!

 

SACU - Can you pull and post the DTC's? This might help us narrow down some responses.

I am sure ya'll know this ...... BUT for the newer 6.0L owners / readers:
Many turbo and EGR related problems are related to (or at least made worse by) preventative maintenance practices and certain modes of operation. There were certainly bad batches of EGR valves and other things, but I constantly read about problems made worse by folks not realizing the impact of certain decisions:

- choice of filters (always use OEM OR OEM equivalent w/ patent numbers)
- choice of oils (CJ4 is designed for EGR equipped systems, synthetic HIGHLY recommended)
- choice of OCI (oil change intervals - keep at recommended 7500 / 5000, synthetic may extend some, but don't push it)
- NO oil additives except HSS (and use this only to treat stiction issues)
- amount of idling
- driving hard before fully warmed up
- fuel additives very helpful (no alcohol and water demulsifier)
- buy good fuel from high volume stations
- allowing cool down time (post turbo EGT) after a HARD workout before shutting down the truck
- keep an eye out for oil leaks and get them fixed - they can affect sensors and many other systems.

Definitely consider the following for improved reliability of the turbo / egr system:

- CCV reroute
- newest processor flashes
- larger turbo drain line
- install gages (specifically - watch boost, EGT's, fuel pressure, and oil temp if you have them)

 

My 04 never gave me a problem. 6 months after I did head studs (out of pocket, ouch) we bought an 5th wheel and needed something bigger. I've only had this truck on the road for about a month and this will be the 4th trip to the dealer. It's got 79k on it and no rust coming from Florida but the oasis report shows that it's only been to the dealer 3 times for repairs only. I knew there was going to be some problems just not this many but sooner or later it will get straightened out. It will be a daily driver and tow a 15K 5th wheel a couple times a year. We just couldn't meet the GVWR & CVWR with the 04.

I did have the dealer do a full service on it. I don't have a code reader but the last dealer said that there where no codes and everything and is working how it's supposed to. I may have to take a drive to Auto Zone. I did install guages and the egt's seem a little high to me (about 100 degrees higher then my 04) but the could just be the difference from a SRW to a DRW. It does have the newest flashes installed.

I need to put a lower/smaller leveling kit (2" now) in it because with the aux tank filled the front sets 1/4" higher then the rear. Then try to squeeze a set of 285/70/17 on it. Like every else I would like to install head studs, egr delete, CCV and tuner but I can wait for the warranty to expire before that happens.

Sorry I can not give you more specifics.

Randy

 

i would put money on the vgt actuator.

 

Well going to the Fleet Service Center was worth the trip. Turns out it had a EBP sensor that was reading low and the VGT actuator had "movement without command", I like how they said it. Both got replaced under emissions warranty at no cost. The truck is running great. Looks like I've found a new dealer to take my truck.

Thank you all for your help & input.

Randy