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It will make like a chuff chuff noise. You will hear it most of the time, light to moderate load. Normally you would hear this on a good turbo under a heavy load/hard accel condition and then a quick release of the throttle.
There is no blow off or waste gate on the 6.0. The noise you hear is boost pressure release through the intake system.
Looks like you need to remove the turbo and have it rebuilt, or do it yourself. There is a write up in the tech folder on how to do it. I am not sure what the kit costs from Ford.
Luckily my truck was still under waranty when it happened to me. The first time it wa sthrowing a low boost code and was farting, they rebuilt it. The second time it needed a center section so it got a new turbo, feed line, and drain pipe. So while you have it out you may as well install these parts too, they are cheap.
I did see a few new center sections on ebay for less that 200.00 but that was a while ago.
Or maaybe call BD or one of the other vendors and upgrade?
I think you have a combination of things going on too. The turbo sticking will still allow you to drive when cold.
Describe what else it is doing when cold, is there anyway you can moniter some stuff for us, like FICM voltage. Also is the charging system up to snuff?
Like stated before, you may want to remove the EGR valve and have a look at it. Also check the intake for any signs of coolant/moisture, if you do deleting/replaceing the EGR and oil cooler would be ideal while you have that turbo out of the way.
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