Returning from a trip today in my 05, pulling a modest 3000lbs and all of the sudden, at 65mph, no boost and complete loss of power. Could only get the turbo to respond, some, by a downshift and a lot of thottle. Pulled over to see if I popped a tube off and found all OK. Back on the road and the truck ran normal.

EGR sticking?? This is getting old!

 

amy smoke or codes.could have a issue with a ebp sensor or wiring chaffing near the connector.usually if the egr valve messes up you will have heavy smoke and no power.

 

Didn't notice smoke this time.

 

Spoke to the service manager today, said the turbo was rusted and the unison ring welded(rust) itself to the housing. Some vanes open, some closed. Rebuilt the turbo with "new" style parts, supposed to have an updated/new coating to prevent rust. Have 89,000 miles on the truck. I'll pick it up today and see how it runs. I know it had a lack of power, somewhat, when towing before, with the bad turbo, so it should be much better now!?!

 

Oh yes....no charge, said it was covered under emissions!!

 

NO deductible is the best deductible.
I think you're turbo is going to get a revised housing that has less flat contact surface on each vane.
Good to know you have found the "no boost" problem.