No power up hill towing, irratic boost gauge, poofing sound under hood? Stuck in PA. - Page 2 - Diesel Forum

imsolidstate · 06-11-2009, 11:05 PM

Since the truck seems to run fine for about ten minutes and then act up, then it's pretty much guaranteed to be an engine sensor that is failing and giving the computer erratic input once the engine is warm and the ECM is looking at the sensors.
I was just going to suggest that in the interest of getting home, you might try disconnecting the vgt control connector on the turbo. I don't know if it fails open or not though. If it fails closed it won't work. If it fails open, then you will be able to drive home with full power even though the computer wants to shut down the turbo (assuming it doesn't defuel or something else). I drove an '03 6.0l that had a stuck-open turbo, and it will still run and make power but it takes forever for the turbo to kick in.
Good luck getting home.

teamroper60 · 06-11-2009, 11:20 PM

The turbo defaults to the vanes wide open if you unplug the VGT solenoid. It would be very laggy that way...

fusaichi pegasus · 06-11-2009, 11:20 PM

Quote:

Originally Posted by EBX

STUCK IN PA, 500 MILES FROM HOME. HELP!!!

The X is 100% stock, accept the pilar gauges. 63,000 miles. Out of warranty, ofcourse.

Intermittently while towing 7000 lbs. up hill, my boost gauge will fluctuate wildly up and down 5 lbs. of boost either way. No power. I also hear a poofing sound under the hood.

This occurs at around 17 lbs. of boost and 1100 degrees on the pyrometer.

Trans. gauge is normal around 160.

1st time, in Indianapolis IN, three weeks ago, after puffs of black smoke out the exhaust and fluctuating boost gauge, dash light came on. Ford replaced the egr valve, cleaned IAT tube and some turbo tubes. They also did the vvt test to check the veins in the turbo and it checked out ok. $1123.00.

2nd occurrance, in Wheeling WV, last week, no puffs of black smoke, irratic idle, no power, puffing sound under hood, at 17 lbs. of boost, 1100 on the pyro. No Dash light. Ford replaced the map sensor. $230.00.

I tightened the turbo hose bolts, replaced air filter, engine oil, drained water/fuel separtator. Fuel filters were changed 12000 miles ago.

I am now stuck in PA. I live in OH. I flew the wife home for work. I have another few days off to get this fixed and get home.

I can't reproduce the issue in tow/haul or not. It occurs when it wants, only while towing uphill with a load (7000 lbs. right now).

Please help get me home.

I will focus on the last part this post and try to explain what you concerns MAY be keeping you from returning home while excusing your later comment refeering that Ford is incompentent. This is a perfect example of why so many Ford techs dont or wont work on the Diesel engine. First of all, Quit wasting your money trying to throw a hand grenade on the problem. It isnt a maintenance issue. The symptom you have is obviously intermittent, Thus,The dealership may have tried to repair the issue due to a known concern, Not YOUR concern. I would not think this is a problem for and independent shop either due to the fact most do not have the resources or the diagnostic tools to find the ROOT CAUSE of YOUR problem. If I were working on your truck I would monitor the Icp v pid koeo. It should be .15-.35 volts koeo. A biased ICP sensor can cause a number of drivability concerns like you describe. A biased Icp sensor can also set a p0299 underboost code. I would also make sure that the new Egr valve was not replaced without making sure that there were not excessive carbon and coking deposits in the intake manifold. Sometimes an Egr valve concern is the end result of the problem and not the source. Replacing the valve will not solve the problem and will buy little time til the concern re-appears. Without getting to technical, Lets remember that the turbo and egr system take inputs from several sensors to determine operation. Without seeing the specific concern happening or seeing an Ids recording it will be impossible to resolve your problem online. I would also recommend that you take all you previous repair paperwork to the dealer with you as some of the replaced components will have a 12 month 12k warranty on the part. good luck and dont lose hope yet !

teamroper60 · 06-11-2009, 11:23 PM

I just learned something new.... I would not have thought of the ICP sensor as the problem! Thanks Shane!

RatherBNtheWoods · 06-11-2009, 11:45 PM

Mine started a similar type thing last summer. It would be fine for a while then go to under-boosting and over-boosting and puff/fart from under the hood. Ford warranty paid to rebuild the turbo and clean up the exhaust side all nice and shinny, the VGT (what ever moves the vanes) the EBP and the little tube it mounts on.

Next trip same thing, they put a MAP/BARO sensor on it.
Next trip(out of warranty) same thing. When it would "act up" I would have to drive via the boost gauge. Get too high on the boost gauge and the engine sounded like it was really straining,( like it had a potatoe stuck in the tailpipe) until I saw the boost fall down(as if something came unstuck) then it would be fine until the next time I needed near max boost.

So, short story long, I'm at a rest area with the hood up cursing the darn thing, (you don't make good time towing the 5er without going over 15-20lb boost) when I noticed the shop had routed the vac line to the heater core valve around the MAP sensor wrong. So, being anal as I am about hose routing and everything in general, I routed it correctly. When my fingers/hands were near the hose that went to the MAP it moved quite easily on the MAP sensor. I thought to myself, you know. A hose that holds upwards of 30 PSI should be tighter than that. And,,,I pondered, if it were loose enough to leak, the PCM would be calling for more boost,,,and hum...I cut the end of hose off just a little, to get to new unused part of the hose, and plugged it on the MAP..........And......
Not another fart/poof/puff or overboost/underboost all the way home!
Since then i replaced the hose, but still haven't had another episode yet.

In short,,,check the little 3/8 or maybe 5/16 hose that goes from the manifold to the MAP sensor. Needs to be good-n-tight. Worth checking anyway.

EBX · 06-12-2009, 10:55 AM

Quote:

Originally Posted by fusaichi pegasus

I will focus on the last part this post and try to explain what you concerns MAY be keeping you from returning home while excusing your later comment refeering that Ford is incompentent. This is a perfect example of why so many Ford techs dont or wont work on the Diesel engine. First of all, Quit wasting your money trying to throw a hand grenade on the problem. It isnt a maintenance issue. The symptom you have is obviously intermittent, Thus,The dealership may have tried to repair the issue due to a known concern, Not YOUR concern. I would not think this is a problem for and independent shop either due to the fact most do not have the resources or the diagnostic tools to find the ROOT CAUSE of YOUR problem. If I were working on your truck I would monitor the Icp v pid koeo. It should be .15-.35 volts koeo. A biased ICP sensor can cause a number of drivability concerns like you describe. A biased Icp sensor can also set a p0299 underboost code. I would also make sure that the new Egr valve was not replaced without making sure that there were not excessive carbon and coking deposits in the intake manifold. Sometimes an Egr valve concern is the end result of the problem and not the source. Replacing the valve will not solve the problem and will buy little time til the concern re-appears. Without getting to technical, Lets remember that the turbo and egr system take inputs from several sensors to determine operation. Without seeing the specific concern happening or seeing an Ids recording it will be impossible to resolve your problem online. I would also recommend that you take all you previous repair paperwork to the dealer with you as some of the replaced components will have a 12 month 12k warranty on the part. good luck and dont lose hope yet !

You have to understand my extreme frustration w/ this situation and Fords incompetance. Especially w/ a vehicle bought brand new for $45k and w/ only 63,000 miles on it. There shouldn't even be any issues w/ a brand new vehicle until into the 100,000 mile area and for a diesel, well into the 100,000s.

I paid a premium for a new vehicle w/ the diesel option for its longevity and qaulity.

If you are an employee at Ford, you may be a good one. But, that is far from my current experience with Ford.

I have lost a week of work, not to mention the "extreme" frustration and anger I have for Ford, their product and their diesel techs so called "expertise".

My perception is that if the techs can't find a code and replace a part, their knowledge stops. Ford needs to train their techs on diognostic skills, not just how to plug in and wait for a computer code.

EBX · 06-14-2009, 07:15 PM

Tech said the diesel tech was able to reproduce the issue 3 out of 4 times. Said possible oil pressure issue. HPOP?????? Injector control module????? I rented a Dodge Ram 2500 to get the 20' enclosed trailer and car back to Ohio. I'll drive back at the end of the week. Hopefully Ford can figure out how to fix what they sell.

Bansheechick · 06-14-2009, 09:13 PM

This is exactly what my truck was doing, only up hilld with a load. Drove great around town. Went up North this weekend and figured it would be ok as long as I was not towing. WRONG. It made a loud "pop" and black smoke rolled out. Black smoke on and off, not consistant. Took the truck to the dealer they told me turbo was sticking and overboosted and blew up my intercooler. Quoted me $2300 to fix it. Brought the truck home.

teamroper60 · 06-14-2009, 10:27 PM

Quote:

Originally Posted by Bansheechick

This is exactly what my truck was doing, only up hilld with a load. Drove great around town. Went up North this weekend and figured it would be ok as long as I was not towing. WRONG. It made a loud "pop" and black smoke rolled out. Black smoke on and off, not consistant. Took the truck to the dealer they told me turbo was sticking and overboosted and blew up my intercooler. Quoted me $2300 to fix it. Brought the truck home.

I think that dealer was "taking you for a ride". See my post in your other thread...

Blue streak · 06-15-2009, 08:12 PM

Sounds like the same problem I was having on my 04. My truck had a recall on the back pressure sensor. The sensor and pigtail were change and the only time I had any pro blems after that is when the grease monkeys a wally world try to play mechanic and plug in the EGR valve. I easily solved that problem by eleminating wall mart oil changes! As possible test to get you home. Turn off the engie, unplug the EGR SYSTEM and test drive.There are three plugs,valve, sensor, and throttle plate accuator.Some will say the EGR is necessry,I can tell you mie asn't been for the last 425K ofthe 525K miles on mine.Good luck

EBX · 06-16-2009, 03:51 PM

Dealer just called and said they need to replace the ICP sylinoid and connector. They will also clean the turbo while it is out. Charge $1350.00.

Is this a fair price? Do you think it will fix the issue?

teamroper60 · 06-16-2009, 04:52 PM

Based on my experience in replacing an ICP sensor and cleaning my turbo, you are looking at probably a full day's worth of time for the tech (figure roughly $100/hr) and the cost of the parts (at dealer prices), that is probably about right......

fusaichi pegasus · 06-16-2009, 11:38 PM

Quote:

Originally Posted by EBX

Dealer just called and said they need to replace the ICP sylinoid and connector. They will also clean the turbo while it is out. Charge $1350.00.

Is this a fair price? Do you think it will fix the issue?

Icp sensor and connector??? You bet ! Turbo ? While its out ? Hmmm?

EBX · 06-22-2009, 09:27 PM

They said the turbo was rusted inside and the unison ring would stick after cleaning.

They replaced the vgt and turbo for $2500. I bought the ext. war. 4 yrs./48k for $2600.

Got the truck home, 550 miles. No issues.

knelson454 · 07-02-2009, 04:19 PM

I've been following your story. What happened with ICP sensor and pig tail? Did they do that too along with the new turbo? I'm real curious as my truck is doing exactly what yours was doing.