No, I don't know the TSB's. Maybe Bismic does if it really exists. Turbo's were replaced due to spec changes in the variable vane clearances to help prevent vane sticking. In a way it almost sounds as if the truck might be suffering from "lot rot" as it only has 46K miles and it's an 04. It is possible that it's still suffering from an EGR problem. It doesn't take that much to jam one open as the spring pressure is very light and once junk starts building up in the intake it can break off in chunks. The intake that I have on my truck now (one I got to modify) took a full day in the vat and a pressure washer to get the nasty out. Not saying his is, but it can happen very quickly with the amount of crap being put back through the motor with current emissions systems.

FWIW--I'm just throwing out ideas from things I've seen and people I've talked to that have had very similar problems to your friend. I'll be very interested to know the results of his repair.

 

Thanks partsman. That's the kind of perspectives and experiences I have been hoping to find out for my buddy. As soon as I can get some word back from him, I'll make sure to post up with the current status of his ongoing saga.

Meanwhile, if any other ideas crop up, I'll still be checking in here and passing along the info to him as it becomes available.

Again, I really appreciate your guys' knowledge and experience, and I'm sure that we will get to the root of this thing.

 

when you start bringing print-outs to the dealer to help diagnose the problem. that's a sign to find a different dealer. as you have already lost faith in their competence.

I strike for a vote of no confidence.

 

thanks to all for the input.

Would any of yall know about, when the barking occurs, I get an extreme loss of power so great that it feels like the brake is being applied?

RDW

 

Well, hold on a minute. I am not near ready to scrap the dealers service dept and tech. I am just of the nature to offer suggestions like the print out. I guess I am some what of a pain in the butt to some people. Pete and I work for an Engineering Company and we're just used to having to help.

By the same token, I am more than willing and thankful for your help. Cant hurt my feelings.

And yes, the previous owner did not drive this truck enuff. It is perfect looking but the dealer and myself have cleaned on the internals. Seem to have it running like a bullet train. All 325 horses are there. Its just this low RPM (1,200) steady driving when in traffic causing this stumble and muting and sometimes barking.

 

The barking you keep talking about keeps screaming turbo fart but at the low RPM's it's happening I'm a little baffled, that's why EGR keeps coming to mind. I'll cut and paste your description and send it to a friend of mine who is very good with 6.0's. He's done over 500 HG jobs, including mine, so he knows his 6.0's.

 

Here is some verbiage from the latest TSB on the Turbo "coking":

TSB 08-16-13


Some 2003-2007 F-Super Duty, 2003-2005 Excursions, and 2004-2008 E-350/450 vehicles equipped with a 6.0L diesel engine may exhibit any one, or a combination, of the following concerns: lack of power, white/black smoke or a surge. These concerns may or may not be accompanied by any one, or a combination, of the following diagnostic trouble codes (DTCs): P0238, P0299, P0404, P0478, P2262 and/or P2263. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE



Coking deposits inside the turbocharger turbine housing can impede vane response causing high or low instances of exhaust pressure. Unexpected exhaust pressure results can cause over-boost, under-boost, insufficient or excessive exhaust gas recirculation, or unexpected EGR valve position, resulting in these symptoms.

This TSB is for diagnosis and cleaning of the variable geometry turbocharger (VGT) vane set and the center housing and rotating assembly (CHRA), and for replacement of a corroded CHRA.
For F-Super Duty, Excursions, and E-Series vehicles built on or before 9/29/2003, follow pin point test KA in the Powertrain Controls/Emissions Diagnosis (PC/ED) manual diagnostics. If the pin-point test in the PC/ED manual diagnostics leads to turbocharger replacement, use this Turbocharger Inspection Procedure first to check for internal turbocharger oil leaks, and to determine if the turbocharger can be repaired with a CHRA replacement, or if it can be cleaned, instead of replacing the entire turbocharger. (Figure 1)

 

Good context around the situation, Mark. Thanks.

 

TSB 08-26-12 6.0L COKING DEPOSITS DIAGNOSTIC—EGR DTCS P0401, P0402, P0404, P1335


Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles equipped with a 6.0L engine may exhibit white smoke, black smoke, lacks power, exhaust odor, surges and/or exhaust gas recirculation (EGR) diagnostic trouble codes (DTCs) P0401, P0402, P0404, and/or P1335 as a result of excessive coking deposits, un-combusted or incompletely combusted hydrocarbons. This procedure should be used only if one or more of the components listed below have already been identified as having an excessive coking condition.

NOTE:
THE ROOT CAUSE OF THE COKING MUST BE CORRECTED OR THE COKING MAY REOCCUR.

After following normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics, use this procedure to identify the root cause of the excessive coking condition and if appropriate install an EGR Baffle. Just replacing the component with coking deposits and installing the EGR baffle will not correct the root cause, and coking will reoccur.

Coking deposits are generally un-combusted or incompletely combusted hydrocarbons, commonly sourced from engine oil or diesel fuel. These deposits can form on system components such as the EGR valve, EGR cooler, exhaust back pressure (EBP) Sensor, EBP tube, intake manifold, turbo charger, catalytic converter and EGR throttle plate.

Visual inspection alone cannot link the sources of coking deposits as either from engine oil or diesel fuel. Coking deposits can be identified as shiny black grease like sludge, hard flat black solid mass or thin light brown sticky layer.

Un-combusted deposits can be linked to delayed combustion events. Delayed combustion events can be a function of hard to ignite elements like poor quality fuel, excessive fuel, engine oil or excessive exhaust gas recirculation in the combustion chamber or a delayed injection event like calibration, wire chafe, injector mechanical issue. Un-combusted fuel is usually evident as fuel scented white exhaust smoke. Un-combusted fuel may create coking which impairs system functionality eventually leading to black exhaust smoke / poorly combusted fuel.

NOTE:
VEHICLE PERFORMANCE ISSUES RELATED TO FUEL QUALITY, MAINTENANCE AND AFTERMARKET MODIFICATIONS ARE NOT COVERED BY FORD MOTOR COMPANY WARRANTY.

Complete all of the following steps. Devices such as the Catalyst, manifold absolute pressure (MAP) sensor and EBP sensor that fail the PC/ED pinpoint tests (PPT) must be replaced and not cleaned. Clean the Turbocharger using other applicable TSB’s, the intake manifold and EBP tube. EGR valves that fail the Integrated Diagnostic System (IDS) - EGR Systems Test should be replaced not cleaned.

 

Great info Mark. This all seems to revolve around uncombusted fuel/poor fuel quality and the fact that someone before me just used this thing to drag a boat to the river on pretty days.(it was a leased vehicle prior to my ownership, and he stayed within his milage. Imagine that!) I am begining to think that I can be in direct control of this happening again in the furture.
The service MGR had been to a training class monday and relayed the Idea of adding "Ctane" (SP) to my fuel to bring the count up above 45. Our pumps here in Alabama are said to be 38, thats low. I will continue to add Lucas every tankfull.

Ya know, maybe a good dose of bio fuel would strip this thing clean? (just kidding)

So far, the turbo has been cleaned. Now how much cleaning it recieved I dont know for sure and wether cleaning included the VGTCV. I now have a new EGR valve and throttle plate, but do not have a new MAP, BARO or EBP (if EBP still applies to my truck, I am a little lost on what MAX said about build dates)

Its friday and usually they drive it home over the weekend to see how it does. I have given the tech my OK to drive, drive, drive. It all free for now.

RDW

 

If your truck was built before Sept 29, 2003 AND you have had the computer software updated (flashed) in the last 3-4 years, then you do not need an EBP sensor (your PCM does not use it in the controls).

 

10-4 Mark. They have installed a completely new PCM last week. So as I understand from yall it now does not need the EBP anymore. But, MAP and BARO are still in the control shceme?

RDW

 

Yes, RDW... the MAP and BARO are both still part of the programming logic.

 

Have you got rid of code p0487 yet.My truck has same code and symptoms
Thanks

 

Since this thread got started, I got laid off by the company and RDW is working out of state, and we've not been in touch very much. That said, I'm not sure if he got everything resolved or not. He normally doesn't get on here at all, so I doubt if he'll even see your question. I'll try to contact him and get an update.