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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 02-14-2006, 07:20 PM   #1 (permalink)
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6.0 exhaust leak

2003 6.0l f-250
exhaust leak, while idling the fumes from exhaust stink up the cab. anybody have any ideas what might be causing this.
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Old 02-14-2006, 07:27 PM   #2 (permalink)
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Re: 6.0 exhaust leak

Check your recalls. I'm not sure if the 2003s are covered by it, but there is a TSB on exhaust fumes in the cab.

Have you asked a service rep about it?

Nate
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Old 02-14-2006, 08:47 PM   #3 (permalink)
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Re: 6.0 exhaust leak

Probably a cracked y-pipe. I saw one of these the other day on an 04/03. Your dealer should be able to fix it, no problem....
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Old 02-14-2006, 08:50 PM   #4 (permalink)
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Re: 6.0 exhaust leak

[ QUOTE ]
Probably a cracked y-pipe. I saw one of these the other day on an 04/03. Your dealer should be able to fix it, no problem....

[/ QUOTE ]



Where exactly in the Y pipe.I was looking on mine 05 and couldn't find it.
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Old 02-14-2006, 08:59 PM   #5 (permalink)
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Re: 6.0 exhaust leak

<font color="blue"> Exhaust Smell in Cab:
If an exhaust smell is present in the cab, inspect for leaks at the exhaust manifolds. Ford's procedure calls for warming up the truck to operating temperature, then shutting off the engine, remove the EBP sensor and use a smoke machine to feed smoke into the exhaust system. Inspect each exhaust port, manifold flange and Y-pipe joint for smoke leakage. I find using a length of hose as a stethyscope while the engine is running works well to pinpoint exhaust leaks. If a leak is found at the exhaust manifold, replace only the manifold gasket that is leaking(I think this should read INSTALL a gasket, since originally there are no gaskets at the manifolds). Gasket P/N 5C4Z-9448-A.
TSB 05-13-9.</font>

The above info is the TSB. I am going to have mine looked at again next week when I take it in for the reflash...
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Old 02-14-2006, 09:08 PM   #6 (permalink)
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Re: 6.0 exhaust leak

[ QUOTE ]
[ QUOTE ]
Probably a cracked y-pipe. I saw one of these the other day on an 04/03. Your dealer should be able to fix it, no problem....

[/ QUOTE ]



Where exactly in the Y pipe.I was looking on mine 05 and couldn't find it.

[/ QUOTE ]

I don't know that there is a specific place on the y-pipe that is most prone to crack, but if you look at it and find soot on it, chances are, you have a crack. If you don't see soot, you probably don't have a crack. On the one I was looking at, the owner had been complaining about the smell at idle. We opened the hood and the first clue was the insulation on the driver's side of the firewall had lost it's shine and was very sooty. We used a mechanics mirror to look at the pipe and saw the soot.
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Old 02-15-2006, 05:31 AM   #7 (permalink)
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Re: 6.0 exhaust leak

I.m not familiar with a y pipe. where is it located. Is this the down pipe coming from the turbo. I am getting to put a 4" exhaust on the truck, but I want to make sure I have located the exhaust leak before I install it.
Thanks for your input
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Old 02-15-2006, 06:05 AM   #8 (permalink)
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Re: 6.0 exhaust leak

The only way to get a really good view of it is with the engine out of the truck... and as usual, the 6.0 Bible to the rescue!

http://www.backglass.org/duncan/ps60...l/ps60_011.jpg

http://www.backglass.org/duncan/ps60...l/ps60_013.jpg

It's easier to see the Y-ness of it in the top views (second link). I believe a lot of the cracking occurs in the flexible joint portions.

Duncan
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Old 02-15-2006, 06:57 AM   #9 (permalink)
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Re: 6.0 exhaust leak

When I took mine in for cab smell along with the recent recall, they siad that exhaust manifold bolts were loose. They tightened them and now the smell is gone.
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Old 02-15-2006, 07:23 AM   #10 (permalink)
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Re: 6.0 exhaust leak

The Y-pipe in reference is the pipe that goes from the rear of each exhaust manifold inward then upward to the rear of the turbo, some of these pipes have expansion sleeves and some don't, some crack behind the turbo allowing exhaust fumes to enter the passenger compartment. There is a tsb on this issue. I am not saying this is your concern, just a possiblity.
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Old 02-15-2006, 08:17 AM   #11 (permalink)
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Re: 6.0 exhaust leak

This is one area on the 6.0 that really "looks" like they saved a few bucks over the 7.3. The y-pipe feeding into the turbo is a welded steel design. It looks somewhat similar to headers, and just before the mate with the turbo the two pipes come together with a weld, and a flange that mounts to the turbo via the clamp. On the 7.3 engines there is no y-pipe. There is a coupler between the turbo, and the two exhaust pipes coming off of the manifolds. The coupler is a casting, not welded or stamped. It has been referred to in production as a "baby-butt" because it's small, and the casting on the backside has a remarkable similarity to butt cheeks. [img]/ubbthreads/images/graemlins/cool.gif[/img]
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Old 02-15-2006, 08:54 AM   #12 (permalink)
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Re: 6.0 exhaust leak

My exhaust problem is driving me crazy. I would get what I believe to be exhaust in the cab only after coming to a stop and idling while waiting for a signal to change. Dealer added manifold gaskets and it seems to happen less frequently but I still get this odd odor (I believe it's exhaust) when the AC is operating or the vent is on. The Service Writer drove my truck home and indicated he believes there is no exhaust leak and the odor is normal. When my family is in the truck they smell it too. At this point I'm going to look for an IAQ sensor to try to prove it's exhaust I'm smelling. (Hopefully I'm not just going crazy from reading about problems on this site [img]/ubbthreads/images/graemlins/cool.gif[/img])
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Old 02-15-2006, 09:06 AM   #13 (permalink)
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Re: 6.0 exhaust leak

How many miles does your truck have on it? I would certainly suggest the sensor method, but there are also 'break in period' odors that I have read about on the 05s and 06s. I never noticed them on my 03, but have read about them going away after so many thousand miles.
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Old 02-15-2006, 09:14 AM   #14 (permalink)
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Re: 6.0 exhaust leak

I probably need to update my sig.

My truck is an 05 with 10/2004 build date. I purchased the truck in February 05 and it now has approximately 8,600 miles on the odometer.

Thanks for the feedback. I'm sure hopeful this can be resolved. Although I have had a considerable number of problems, I really love driving and towing my 5th wheel with this truck.
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Old 02-17-2006, 10:32 AM   #15 (permalink)
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Re: 6.0 exhaust leak

[ QUOTE ]
I probably need to update my sig.

My truck is an 05 with 10/2004 build date. I purchased the truck in February 05 and it now has approximately 8,600 miles on the odometer.

Thanks for the feedback. I'm sure hopeful this can be resolved. Although I have had a considerable number of problems, I really love driving and towing my 5th wheel with this truck.

[/ QUOTE ]

My 05 has an 11/04 build date and i have this same prob with the exhaust smell.

I am sittin here right no i'm wondering why i have to do all the work for the service writers.Just got off the phone with him and he says theres no tsb's regarding this issue or for the droan/vibration i get at about 1750rpm.Why is it that we dieselstop members have all this info and the dealer(service writer)doesn't.I just don't get it.
Now i'm gett'in myself all worked up .Guess i'll have to get the tsb numbers and forward them to this guy so i get get my truck fixed.I may have to send them a bill for my time!!!
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