[sixLiter1FT]

Well it starts already...

I bought a used 2005 F250 at the beginning of the month at my local Dodge dealer. 60k miles and in great shape. The first week i had it I put in an Edge insight and a Dieselsite coolant filter hoping to nip the EGR problems in the butt before they start. Immediately, the EOT and ECT were consistently 17-20 degrees apart at highway speeds. Yesterday, I started the truck and realized there was a problem. The truck threw so much white smoke out of the exhaust I thought someone elected a new Pope. The the engine began bucking and sputtering. I pulled over, popped the hood, and found zero coolant in the degas tank. It was full 2 days ago. I had it towed to the dealer where it's still under the 30 day warranty.

So here is where I ask the advice of the forum:

1. This does sound like the head gasket, or at least the EGR cooler, correct?
2. The dealer says they'll take care of it, but should I trust a Dodge dealer to know how to properly fix this? (oil cooler and EGR cooler as per TSB?)
3. If I can trust them to fix it, should I see if they'll put in stronger head studs and gasket and a better EGR cooler if I offer to pay the difference in parts?

If anyone has any direction or words of wisdom, it would be greatly appreciated. I'm so bummed about my truck.

 

[ex mounty]

Google TSB 09-8-3. Thats the TSB for coolant loss and will help them determine what that actual issue is.
Present it in a gentle manner if you want to directly give it to them.
Maybe ask them to give you a call when they determine what it is, and if it is head gaskets, be sure the heads are removed and checked for straightness/flatness and magnafluxed for cracks. They are well known for cracking in the valve seat area.
Dodge dealer would probably be OK with installing the headstuds if you get them first.
My issue with this whole thing is getting them to do the job properly.


My guess is that the truck was traded in knowing that this problem existed and they didn't want the expense of fixing it. If it was caught early enough, it might only be the oil cooler/EGR coolers.

 

[xpbprox]

yup they sure do crack, mine were cracked on the valve seats so the machine shope put in hardened valve seats.
when i did my studs i replaced the stock egr cooler for one from bulletproof diesel
and if you did blow the gaskets then i would have them put studs in while they are in there.
also regardless of whether its the head gaskets or the egr cooler, you need to make them replace the oil cooler. it would be good if you could post your actual tempatures for the oil and coolant

 

[OT]

Geez, tough way to start off eh! But, welcome anyways. You can print this out 6L Coolant loss/testing etc. Like ex says "getting them to do it properly" is ongoing complaint/concern with 6L (dealer/shop) repairs.
DIY u can only get mad at yourself! :icon_wink:

Many reports here on "numerous trips to fix same problem" & those being done by :ford: tech's, not dodge. Lots of info. here you can print out & use if needed. I've done same, but chose my words carefully when I talked to tec.? It might get complicated, hopefully not. Update if u can. Good luck!

 

[WaWheeler]

I feel your pain. This happened to me 4 months after I bought mine. Unfortunately for me there was no warranty at that point. $5K later I ended up with new studs/gaskets, egr delete, oil cooler etc. I just got it back yesterday and it runs fantastic. Make sure the heads are checked, one of mine was out .005 they were able to mill it flat so I didn't have to buy a new one. Also, Call Mike at Tousley ford and get any improved/updated parts since they have it apart anyway its worth the little extra now.

Good luck

 

[sixLiter1FT]

Thanks for the insight, I'll keep everyone posted when I hear something. Since I put the Insight meter in, my ECTs were in the range of 184-190 degrees. EOT was around 204 to 209 but as high as 212 at times. Mostly it would be 17-19 degrees apart while cruising but would creep apart at times. I printed out the TSB and will discuss it with the dealer as soon as I talk to them. Hopefully they have a good diesel tech.

 

[03powerstrokeuser]

Ahhhh, The Dodge Boys. I have trusted mechanics in the states I tow in. One is in Spartanburg / Greeneville SC. A Dodge Boy, and one of the most insightful and talented 6.0 guys I have ever met. PS, I don't always carry my tools. b

 

[lubbockguy1979]

Sounds like at the minimum a egr cooler and oil cooler. A good flush. I would however push for head gaskets and the whole show. If pushed I would buy the arps. They can be had for about 400 bucks shipped. thru various places.

 

[sixLiter1FT]

The Dodge dealer called today. They acknowledged that the job is over their head and they're sending it to the local Ford dealer. The tech at the Ford dealer said he put his kids through college doing six liter repairs so it seems like things are going well. I'll keep everyone posted...

 

[ex mounty]

Keep in close contact with the Ford Tech if you can. Might want to find out asap if the heads are coming off so you can have the ARP studs ready for the re-install.

 

[OT]

SixL...OK, so now its wait time till tech. has in bay for diag. As mentioned try & keep close contact. SA usually go between, but maybe tech. will talk with you? 30 day warr. certainly a plus & hopefully gets fixed right. Update on diag. if u can? Good luck!

 

[mwilbur516]

I hope it works out for you. I had problems with mine as soon as I bought it too. After it was properly fixed, it has been a pleasure to own. The aggravation was worth it. I had to deal with a Ford dealer that was completely clueless. The second dealer I took it to had it diagnosed and fixed in a week (ARP's, Gaskets, ICP sensor o-rings, EGR and oil coolers). Stay in contact with the tech that is working on your truck. Push for new head gaskets and buy the ARP's (especially if you plan on any, even mild tunes). What year is the truck? If the Dodge Dealer is paying for the repairs, it may be easier for the tech to get you the whole nine yards (Studs, Gaskets, EGR and oil coolers, and whatever other upgraded parts that you choose to purchase.) Again, I hope it turns out as good for you as it did for me.

Alright just reread your first post and I see its an 05'

 

[alha]

The Dodge dealer called today. They acknowledged that the job is over their head and they're sending it to the local Ford dealer. The tech at the Ford dealer said he put his kids through college doing six liter repairs so it seems like things are going well. I'll keep everyone posted...

sixLiter1FT, any good news yet?

 

[sixLiter1FT]

Still no news yet...

I just called the Ford dealer today and they told me that they haven't looked at the truck yet. It's been 8 business days so far, I'm beginning to wonder if I'm being jerked around...:worried:

 

[a19berning]

Sounds like it. My ford dealer in martinsville gets mad if they dont have it in within two days. They rock and have amazing techs there though. Hope everything works out. I would ask them why it hasnt been looked at yet.

 

[sixLiter1FT]

The saga continues...

I heard from Leo Kaytes Ford today. They told me that they had diagnosed the problem as a faulty EGR VALVE and were pleased to announce that the repair would be done today...:icon_confused:??????

First off, how does it take 3 weeks to change an EGR valve? On top of that, I don't know of any way that a faulty EGR valve can cause my coolant to blow out of the exhaust. Am I wrong? I questioned the service manager thoroughly and he was adamant that the EGR cooler appeared intact. I reminded him of my initial complaint of white smoke and an empty degas bottle and he said he would "double check" it.

I've had it. I've been more than patient with them so far, but 3 weeks without a truck with zero progress is insane. I'm going to go visit the dealer in person today, wish me luck.

 

[a19berning]

Good luck! Keep us posted. I feel bad for you. I woould die without my truck.

 

[ex mounty]

I heard from Leo Kaytes Ford today. They told me that they had diagnosed the problem as a faulty EGR VALVE and were pleased to announce that the repair would be done today...:icon_confused:??????

I questioned the service manager thoroughly and he was adamant that the EGR cooler appeared intact. I reminded him of my initial complaint of white smoke and an empty degas bottle and he said he would "double check" it.

The TSB for coolant loss is VERY CLEAR. Go to this link: TSB 09-8-3(originally posted by OT)

Print that out and bring it with you. Hand it to the service advisor and ask what steps of the Ford TSB for coolant loss says to "replace egr VALVE?"

 

[sixLiter1FT]

week four and still no truck...

Since week four has come and gone, I figure it's time for another update...

On Friday the 20th, after 3 weeks without a truck, the dodge dealer called and said that my truck was "fixed" and ready to be picked up. I showed up that afternoon and, being skeptical, requested that I test drive the truck with the service tech before signing for the repair. I test drove it hard, and there wasn't a puff of smoke, nor did the coolant level drop at all. I was baffled, maybe the Ford dealer actually fixed it.

Then I saw the invoice: "replaced EGR valve and serviced intake manifold"- $600-something dollars (thankfully covered by dealer warranty). I thanked the service manager, told him that I'll be back when it starts smoking again, and took my truck home.

Whatever they did lasted for 2 whole days. By Sunday it was smoking again, same as before. I went back to the dealer on Monday and told them that the band-aid fell off. We had a civil conversation twak at which time I told them I was not leaving the service counter until they had some answers for me. After about an hour, we agreed that the truck would go to one of the local diesel shops for repair, on their bill.

I stopped by the diesel shop yesterday afternoon. My intake was off, a ruptured EGR cooler was sitting on the bench, and the truck was waiting for new parts. It looks like my truck is finally getting fixed right. The mechanic, though familiar with the TSB, said that he couldn't verify that the oil cooler was bad for warranty purposes, so I asked him to order a new one on my bill and install it anyway while everything was torn apart. I also requested that he flush the coolant when all is said and done. Once it's together he'll check for head gasket failure, but if all goes well I should have my truck tomorrow. :clap::clap::clap:

My fingers are crossed...

 

[ex mounty]

Good luck. Keep us updated