You might want to check the air to air cooler by pressure testing it. If it's not holding pressure due to a crack or boots having a hole in them. The turbo needs back pressure to keep the seals seated. I ran across this on a series 60 Detroit engine. Do you have a boost gauge on the turbo? If you got an air intake side leak you will not build boost. Just a suggestion, I got about 30 years exp. on eighteen wheelers. I also own a F350, 2002, 7.3, 4x4, crew cab, dually and love it.
I replaced all those pretty blue expensive boots just less than a year ago when I did the ELC coolant change over; they also looked good and I torqued all the CAC clamps to 9 ft. lbs. The boost gauge I have is the stock one and functioned as normal as it ever was. The truck was driven and it did not seem to lack power; however I would imagine I might still have have air in the oil system. I customer at my job told me a guy he knew went through 2 turbos on his construction equipment and found out it was lack of oil pressure getting to the turbo.
If that was the case with our trucks, I don't think it would run that great, or run at all.
How would you go about pressure testing the system anyhow. The intercooler is a critical part of this system which you hadn't mentioned, but If it had cracked it would be noisey right?
The Auto Enginuity comes in Tuesday and I will check the injectors, HPOP pressure, IPR, I replaced the IPR valve and upgraded the wiring, oh yeah replaced the EBP sensor because it is recommended with turbo.
The company I bought the turbo from wants me to remove the turbo and ship it back (45 lb. box) that way they can inspect it and determine if its a defective unit or not. Pretty cut and dry so far, but I will remove it after the AE test and I will take pictures and post them as well as send them to the company.
Now for my brand new muffler which probably has fiberglass packing inside it covered with oil and the driveway that has oil on it now too.
I am also waiting on the Blackstone Labortories sample kit that way I can bottle my oil sample and make sure nothing else is wrong. The truck only has 55,000 miles and I change the oil every 3000 - 4000 miles with Castrol Hypuron 15W40 and before that the Motorcraft stuff. I am anal with maintenance on this thing, I know it is not a lack of maintenance too.
I will keep everyone posted.
2006 F-250 6.0 Crew Cab
Red ELC Coolant, Sinister Coolant Filter, CCV Re-route, 6.4 Fuel Banjo Bolts, Fuel Regulator Blue Spring Update, Tint, High Idle Mod, Zoodad Mod, Kenwood, Infinity, Autometer, 4" MBRP Turbo back, No Cat, Sinister EGR valve & Cooler Delete, SCT SF3, Garrett Stage 1 Powermax Turbo, Updated 1 Pc. STC Fitting, Fumoto valve, Updated FORD Oil Cooler, Gates Fleetruner Belt, Blue Anodized Fuel & Oil Caps, HFCM Plug upgrade, DEI Thermal wrap