Problems with 2004 F350 Turbo - Diesel Forum

lhasalover · 05-08-2005, 06:15 PM

I'm curious if any of you have had problems with the Ford F350 6.0 Turbo Diesel engine. We started on a week-long trip and as soon as we got on the freeway, the turbo gave out, the truck ran, but at 30 mph. Took it to the local Ford dealer where they replaced the turbo and said they had replaced 3 in the previous week. This new turbo worked for about 500 miles wherein it died. We took it to another Ford dealer in the area. They said the hose had not been tightened enough by the previous dealer. They tightened the hose (the one which connects the turbo to the engine). We drove for 34 miles and the hose came off. Went to another Ford dealer where they said the hose hadn't been tightened enough. They tightened the hose. We drove about 130 miles and the hose came undone. We phoned the last dealer who said it would be ok to drive the truck despite the black smoke pouring out the back. We made it home driving 60 mph on the flat, 25 mph up the Grapevine (Southern California). Never mind what our letter will say to Ford. Obviously there is a very defective turbo/engine combo. We've loved the truck up to now and have 16,000 miles on it, no problems until now. All 3 dealers were trying their best to help and stopped everything to help solve our problem. The problem is with the manufacturer. If any of you have had a similar problem, I would be interested in knowing. You may email me privately if that is possible on this forum. I sent the same message to the Open Roads Truck Camper Forum and was referred here. Thanks so much for your help and advice.

rebuilder · 05-08-2005, 06:39 PM

Get used to it, it will happen when you least expect it you need to take apart and clean the inside of the hose will some sort of carb cleaner or laquer thinner and reinstall The last time mine did it drove right up to dealers front door and they took one off an 05 which by the way was finally improved it was stapled to the hose itself eliminating one way of coming off it can still slide off the tube if not cleaned properly when reinstalled I had ordered a new and improved hose that I was told updated my existing 04 one and gave to the dealer for the one they took off the 05 and it was just like my 04 old one. There are better ones on the 05 get one of those if you can.

ozhoo · 05-08-2005, 07:00 PM

Your problem is result of the bean counters trying to save $1.47 Seems like if those dealers really wanted to fix it right, they would have. Plenty of 04 have had their IC hoses updated. Here's the info from the TSB. If it were me, I'd replace the intake elbow with on 03 (aluminum) version.

Intercooler Hose Blow-Off:
On 2004 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, this may be due to the clamp being under torqued or damaged. Clean the outside of the intake manifold inlet and the inside of the hose or pipe. On trucks built from 12-15-03 to 4-1-04 replace the cold side pipe assembly with P/N 5C3Z-6C646-BA. On trucks built after 4-1-04 inspect the clamp, and if it is damaged, replace it with P/N 1C3Z-6K786-BA. Seat the hose/pipe onto the intake manifold and torque the clamp (6 ft/lbs 12-15-03 to 4-1-04; 9 ft/lbs after 4-1-04). Broadcast Message 1329, TSB 04-20-9.

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lhasalover · 05-09-2005, 11:58 AM

Thanks for the responses about the hose problem. The truck is now at the local dealer so I'll let you know what happens. We'll forward your advice to the dealer too.

mxdirt426 · 05-10-2005, 12:21 AM

The turbo charger on my 04 Ford 350 diesel was just changed. I drove 100+ miles and felt the truck hesitate once in the mountains. Then coming home from a city over the truck would not break 70mph and I noticed a bunch of smoke like you mentioned coming from my tail pipe, then it finale blew out all the exhaust and kicked in to gear. Boy did my wife eat a bunch of it since she was following me.

I just got my truck back from repair about a week ago. I am going to call Ford tomorrow to find out what may be causing this. But, it sounds like it is still the turbo charger since I seem to be getting the same symptoms as you are having with your truck.

This may be the third time in a month taking my truck in for a repair. The first time the truck was leaking the red transmission fluid and it had an oil leak from the previous inspection during the oil change. They called me after I took the truck in to let me know there is 5 oil leaks and 1 transmission fluid leak. That was fixed and has not been a problem so far.

I hope I can get this resolved.

steveg302 · 05-11-2005, 07:59 PM

I have a 04'Powersroke with 6,000 miles on it.2 weeks ago I didnt even get out of my neighborhood the truck shifted hard twice smoked some then seemed to have lost all its power!!!Also made a terrible noise when accelerated hard and let off.Took truck directly to the dealer.They recalibrated the transmission.It seemed better but still didnt have the power it had before and still made the noise.It is currently at the dealer.He says he has 5 trucks with similar complaint on power lose.They have a turbo on order for mine.I hope this fixes the problem but after reading some of your responses Im sceptical.

Thanks
Steve G.

rmjmotorsports · 05-12-2005, 12:59 AM

It's the mechanics, sorry to tell you that. I'm an aircraft mechanic where were not really able to simply put a hose on and let it go and keep doing it over and over.

First dealer should have taken it apart, looked at the hose, cleaned the hose surfaces and looked at the pipe as well as the CLAMP. If all checked good and was tightened properlly and with a little common sense it would have stayed on longer then it did. Seriously it would have.

I'm not saying there may not be a design flaw but generally it lies with crappy mechanics not seriously looking into the why it happend instead are all looking at just simply getting it out of there hair.

Sorry but I have seen it all too often. Thinking of what they get paid to do what they do and what I get paid to do what I do, it's ridiciouls, but that isn't for this topic.

lhasalover · 05-18-2005, 01:38 PM

Here's the update: We got the truck back from the dealer. He said that the hose had "collapsed", replaced it. It works now, but we'll see.....

steveg302 · 05-19-2005, 06:48 PM

Update The dealer had my truck for twelve days.They replaced the Turbo and it runs great again!!!The dealer did have 5 trucks all experiencing the same complaint LOST POWER!!!Mine seems to be fine now!!!

Steve G.