EGR Cooler out twice in 6 months

[bismic]

Originally Posted by Strokin' 6.0

Just got a call from the mechanic....warranty doesn't cover the EGR cooler, because it's not an internal component of the engine.

I'm trading this truck today....I've had it.

I understand the time expiration of the warranty. The statement on the EGR cooler did not make sense - until you explained the NON-Factory Warranty. What is a D/C extended service contract?

[Montesa]

Originally Posted by Gofasterdammit

Toyota is too green to come out with a full size diesel truck, plus the only company that would power it would be Navistar (once the Ford contract is up next year) or Isuzu since the D-Max is extinct. And then you would have the same reliability issues as Ford and Chevy did.

Toyota has a HUGE line of diesels at their disposal. There would be utterly no reason to go to Navistar or Isuzu. Outside of North America a significant percentage of Toyotas and Hinos are diesel.

Take a look at the engine in the Hino 338. Inline 6 at 260 hp, 585 ft lbs. They also have a lighter weight twin turbo V8 4.5 liter diesel in the overseas Landcruiser among other light duty diesels. They've been in the game for a long time.

[Strokin' 6.0]

Originally Posted by bismic

I understand the time expiration of the warranty. The statement on the EGR cooler did not make sense - until you explained the NON-Factory Warranty. What is a D/C extended service contract?

Because I bought it from a Dodge dealership, I received a Daimler Chrysler (D/C) extended service contract...didn't pay for it, thank God, but it sucks that they pick and choose what's covered and what isn't. Of course, they're going belly up, so I guess they need to scrimp and save where they can.

[Gofaster23]

Originally Posted by Montesa

Toyota has a HUGE line of diesels at their disposal. There would be utterly no reason to go to Navistar or Isuzu. Outside of North America a significant percentage of Toyotas and Hinos are diesel.

Take a look at the engine in the Hino 338. Inline 6 at 260 hp, 585 ft lbs. They also have a lighter weight twin turbo V8 4.5 liter diesel in the overseas Landcruiser among other light duty diesels. They've been in the game for a long time.

I meant too green for the US. To me, the general public looks at Toyota's Prius's and ect. and expect a reliable car with great fuel economy. Out here in California there are a ton of Prius's on the road. My take is that some of them are crazy. One of my friends with a highly tuned 6.0 was blowing black smoke on the freeway while passing and a Prius owner actually followed him 5 miles to a gas station where he proceeded to tell my buddy how he was single handidley destroying the environment. By tell I mean yell. Imagine what that Prius owner would say when they go to the local Toyota dealer for service or to look at a new model and see the new Toyota Thundra LD Diesel but with no fuel economy ratings on the sticker. I couldn't see them getting any more than the U.S. automakers for a LD truck so expect maybe 14 or 16 max mpg on the highway. That super green crazy Prius driver would have a fit. But I am aware of Asian and European market Toyota diesels, they are bullet proof. Just too much hastle for the U.S.

[Gofaster23]

Originally Posted by Strokin' 6.0

Because I bought it from a Dodge dealership, I received a Daimler Chrysler (D/C) extended service contract...didn't pay for it, thank God, but it sucks that they pick and choose what's covered and what isn't. Of course, they're going belly up, so I guess they need to scrimp and save where they can.

Talk to DC again and threaten legal action. Push them hard. See if they have a list of parts covered since the EGR cooler is considered a part of the emissions system. Try calling Ford Customer Care stating that you felt the truck wasn't repaired properly when it was at Jim Bass Ford in August of 08. The complaint they have listed is: MINOR DIESEL ENGINE CONCERN CHECK DEGAS BOTTLE LOW ON WATER APPEARS TO BE OIL IN WATER. They performed TSB# 08-11-03 and deemed the degas bottle cap required replacement. Now how is a degas bottle cap going to account for what appears to be oil in the coolant and a loss of coolant? Maybe if the coolant was venting out of the cap but the degas bottle would be covered in dried up coolant. TSB# 08-11-03 is obsolete now but basically it went: Check degas bottle and cap. Test EGR cooler with vacuum (they did that) if no vacuum present, remove EGR cooler and pressure test on bench and also test oil cooler with vacuum, replace oil cooler if restricted. If they EGR cooler indicated no leak (held vacuum which they said yours did) then they were supposed to perform a road test with a PVT installed in the cooling system to monitor cooling system pressure at WOT and also check the difference between the ECT and EOT PIDS. According to what's claimed, they didn't do that, in fact they didn't claim time to replace the degas bottle (crappy warranty clerk or they are in warranty time out). If the cooling system pressure was less than what the degas bottle cap released at and the ECT/EOT split was within spec, then the truck would be ok. They only did a partial repair, IMHO. If it has had the same problem since you picked it up after degas bottle cap replacement, Bill Bass Ford did not find the root cause of the concern. They just threw a band aid on it. It has still been less than 12 months since then. It's worth a shot.

[Strokin' 6.0]

Thanks for the good info, Gofasterdammit, but I don't ever want to deal with Jim Bass Ford ever again. Their Service Manager came from some jap car dealership and doesn't know crap about Fords, the techs could give a darn whether the job is done right and I just don't have the time to give them my truck for three weeks again, which is how long they kept it when they were messing with the degas bottle cap.

Kenner's Diesel Service is the only place I trust in San Angelo to work on my truck now. David Kenner is an honest and knowledgeable guy who will tell you like it is. He's the one who said that the best thing to do is "fix" the EGR once and for all. I ordered an EGR "fix it for good" kit from River City Diesel...from what I've read, it's a really good system. Once the EGR is "fixed", my EGTs should drop about 200*, from what David said.

I just really hope that I don't have anymore problems with coolant, once the EGR is "fixed". The EGR itself was completely covered in soot mixed with coolant residue.

[69cj]

You also need to alleviate the oil cooler problem with a coolant filter. JMHO.

[Strokin' 6.0]

I'm putting one on, as soon as I get the cash...we're so tightly budgeted right now, down to the penny. The one thing I did do a few weeks ago was have David flush the cooling system out and replace it with Fleetrite ECL...it's what IH uses in the VT365.

[wawrd1]

Just dropped my truck off at the dealer. Since reading some other posts here I decided to check with the dealer in regards to warranty coverage before I gave up the truck. Seems the repair will be covered regardless of whether its head gaskets or EGR or both. I bought the Ford ESP plan and would suggest it to anyone out there with the 6.0 time bomb. Shop around if you are going to buy the plan. The cost will vary from dealer to dealer.

[JW350]

Originally Posted by Gofasterdammit

...TSB# 08-11-03 is obsolete now...

What is the current TSB for these problems. Can you post a link to it?

Thanks!

[Gofaster23]

Originally Posted by JW350

What is the current TSB for these problems. Can you post a link to it?

Thanks!

I couldn't find any links that did not require a password but the new TSB is 09-8-3. It is esentially the same as 08-11-03. The updated diagnostic procedures are: If the EGR cooler fails the off vehicle test, the oil cooler service kit must be installed no matter what. The oil cooler is no longer tested with vacuum, it is now tested by performing a road test and monitoring PIDS, that is if the EGR cooler passes the on vehicle leak test. There are also several turbo boost tests performed before cylinder head gasket replacement. More time for the tech to flush the cooling system and recondition the turbocharger if necessary.

[JW350]

Thanks for the info!

[bismic]

Originally Posted by JW350

Thanks for the info!

send me a PM w/ an email address and I can send you a copy of the TSB.

[Strokin' 6.0]

First hit on Google....here it is.

[Strokin' 6.0]

Ordered my coolant filtration kit from dieselsite today. I should get our truck back from Kenner's tomorrow...they're still waiting on the fan clutch to come in. I'll put the filtration kit on, probably next weekend (it's coming UPS Ground), and then take it back to Kenner's at the beginning of next month to get the EGR "permanent fix kit" I ordered, from River City Diesel, installed.

Since our truck is bone stock, I don't see the need to put head studs on, but one day down the road, when I get debt free, I'll probably splurge for some A1 H-11 studs....of course, if I'm debt free, I'll drop that 610 Cummins in