Okay, I bought my truck with 93,000 miles in April and it has basically been in the shop ever since. I did have the EGR cooler and oil cooler replaced in July. The radiator was cleaned in May and has the latest flashes in August.

From the get go, it has been running hot. Started with water temp gauge going through the roof at 40 mph on a pass towing 7,000 pounds. That led to the radiator cleaning.

Then the fan clutch was still running, leading to the oil/EGR cooler. After that work in July, the fan clutch would still come on unloaded, just have to get the turbo over 15 psi for about 1 minute. It happens while towing any mountain pass, as in the entire uphill portion of the pass. So I got the flash updates and my truck had no codes.

So the weekend after labor day, I went on a 1,200 mile driving towing my tow hauler, had about 8,000 pounds. There is 4 passes on the drive and on the first one, it started sputtering after hitting 1,200 degrees from EGT for more than a minute or so. Basically, I have to let of the gas until it drops to 1,100 degrees, then I am fine as long as it does not get higher than that.

So I take it immediately to the dealer, and they think fuel pump, but can't look at it on a Friday night. So I take it to a different dealer last week, who tows it up a 6% grade several times, but with only 4,000 pounds or so. It did not sputter and fuel pressure was 42 psi, which they said it a little low, but they did not test the pressure while towing. I took it out this weekend and it sputtered again, after riding 1,200 degrees for about a minute. Other than that, the truck drives fine, though appears hot. 70 mph on flat ground unloaded it is about 1,000 degrees.

Does anyone have any thoughts? I am on my last straw with this thing. I want to do the EGR delete, 4 inch exhaust, and SCT tuner, but want to get it running right first.

Thanks in advance!

 

replace the fuel pressure regulator on the small fuel filter housing.the low pressure will cause a sputter the pressure should be 50 psi.

 

Yeah, I just read about that two nights ago. I hope it is that easy. But would that only cause problems when running hard? I only notice it is running hot, no sputtering unless I have a load on a pass. I can do 70 with a load on flat as long as EGTs stay under 1,200.

 

Does it puff any smoke when it sputters? 42 psi is low enough to cause issues with the 6.0, it should be no less than 48, I prefer over 50. That is WOT driving down the road, not loaded. If it is puffing black smoke it COULD be an EGR valve. How much boost is the truck making max?

 

Registering to thread.

I just got back last night from a fishing trip pulling my boat through 40 to 55 mph winds and had the exact same thing. I would like to get to the bottom of it. I thought it was just some turbo farting but now reading this I am concerned that it may be fuel related.

I was running pretty steady 20psi boost most of the way home on flat ground. Up to 30ish pulling hills and that is when it would sputter a bit.

 

I post whenever I read sputtering/chuffing/puffing posts, mine went on for 20k miles before they checked out the turbo vanes, and they were rusted up. They replaced the center hub and all is good. EGR valve and baro sensor are possibilities in order of priority also, but I am no expert. Sounds like others don't like that fuel pressure either. Hope you get it solved so you can enjoy your truck.

 

Not trying to hijack or speak for the OP but I know my turbo is in good shape. I just had it all apart and cleaned less than 2000 miles ago.

Any other possible guesses?

 

Yeah, thanks for the responses. My turbo psi gets up to 28 when pulling hard, and gets there easily. Would it get that high with rusted veins? And would any of this cause the hot temps? Just asking because the dealers around here don't seem to have a clue.

Honestly, I am amazed none of the dealers can figure this out even with a computer hooked up.

 

Jason, the more discussion, the better!!!

 

A stuck unison ring can cause low boost or high boost. It depends on where it gets stuck. 28 is not unheard of but is a tad on the high side for a stock 6.0.......I have seen a couple trucks with stuck unison rings overboost and actually blow open the EGR valve, causing a "sputter" situation. If it stays stuck for a while (not saying yours is) it can blow the passenger side tank off the charge air cooler. Probly need a frame mounted fuel pump also due to the low fuel pressure. 42 psi can lead to injector malfunctions.

 

Cool.

From what I know about the 6.0 it sounds like you may have more than one thing going on. The high EGT's and engine temps would point to EGR and oil cooler problems. My truck was running hot when EMPTY and I spoke with my dealer and got nowhere! I did a ton of reading here and got allot of help. I found a good local diesel tech and did quite a bit of work to my truck. now even pulling my 21' boat my cooling fan does not come on.
If I were you I would take a look at temp rise accross the oil cooler and see if it is within specs. I think it was something like 12 degrees? Anyway that seems to be a real common issue. New oil cooler, EGR cooler and Valve is one option.
The other would be to delete the EGR cooler, new oil cooler and larger turbo back exhaust. That will most likely cure your high temps issue.

Now for the surging........ Not sure yet what to think. I have been concerend about fuel pressure also like you.
I assumed that the surging yesterday was from one of two things. One being possible turbo fart and the other possible low fuel pressure. I think it is one or the other just not sure. I have the tripple pod for the gauges and an EGT gauge,,,,,, Now I think I am going to get the fuel press gauge so I can watch it a bit closer and go from there.

Unless anyone else has some additional ideas to check I am going to rest on the idea that we both may have a fuel related issue/turbofarting problem.....

Please post with your findings and I will gladly do the same.


Take Care,

JT

 

I have new oil and EGR coolers as of July, so theoretically they are good. At one point when I had the dealer last week towing the sled trailer, they were about 15 degrees off, but then went back within 10 degrees after we got to the top.

I am doing at lease the 4 inch exhaust and SCT programmer, but want the truck running right first.