03 550 6.0 with issues, see what you think

Joey Kaylor · July 7, 2006

got finished a few weeks ago with an 03 F550, no start. wound up being the front seal on the HP oil pump blown out, replaced it, turbo due to shaft wear and hitting the housing, EGR cooler cause it had a small crack that looked like it would break, IPR due to metal shavings in it, and the IPS cause it was leaking.

cust drove it about 500 miles so far, and came back in for a blown clutch line. he mentioned it was surging intermittently, it was kinda light but noticable. the guy that was behind him said that the truck was smoking black when it did it "cause the turbo aint workin"

i pulled some codes last night while waiting for the master/slave, and got:

current codes:

P0683

P0132B

KOER codes:

P2263

no KOEO, no codes for balance test, or buzz test either.

i cannot find a definition for 132, the 683 is glow plug issues, and i am chasing that one, but the turbo performance code is worrying me, cause that definately will cause what this dude is saying.

anything in particular i should look for? i dont have an IDS, just a mentor, so i cant check the VRL_LRN PID (i think thats the one for the turbo relearn, i have it written down at work)

Joey Kaylor · July 7, 2006

got the clutch working now, so i will test drive this beast and see what is going on. one thing i did notice was the degas bottle has a small crack in the bottom, leaking onto the IDM. i wonder if that was making it not happy and killing injection?

Jim Warman · July 7, 2006

For a better understanding of what 06E17 does, look at this

http://www.forddoctorsdts.com/bulletins/Inferred_EBP_Functional_Overview.pdf

and this

http://www.forddoctorsdts.com/bulletins/Technician_QA_for_pre-releaseHL1.pdf

These and other documents are available on PowerStroke Central on the PTS website. Kieth posted these in the 06E17 thread in the FSA - TSB -SSM forum as well as the PID overview.

If you are working in a Ford store, you should have access to the PTS website as well as access to OASIS....

FWIW, using OASIS, you can enter the DTCs in the symptom code areas and OASIS will search for any pertinent documents in FSAs, TSBs and SSMs (but not in training or informational materials).

If these websites are available to you (and I'm not saying they are, I just want to prove I'm a dork in real life, too), I'll say the same thing I say to my guys.... if you come to me with a question, you better be waving an OASIS report under my nose and have the appropriate manual open on the SBTS.

Keith Browning · July 7, 2006

I'll say the same thing I say to my guys.... if you come to me with a question, you better be waving an OASIS report under my nose and have the appropriate manual open on the SBTS.

Thank you Jim. I now have a new catchphrase. /forums/images/%%GRAEMLIN_URL%%/hammer2.gif

blown99 · July 7, 2006

What about an EGR valve? Does the ford diagnostics have the ability to graph the EGRP and the EGRD? Was the EGR cooler leaking internally also, causing the muck to build up in the intake and possibly plugging the EBP sensor and tube. I've been finding a lot of the VT 365 EGRP not matching the desired and they don't throw codes for this, (at least in the internationals).

Joey Kaylor · July 8, 2006

no, the cooler wasnt leaking internally, at least not that i could see. the EGR ports in the intake looked good, the valve had been replaced last year about 20k miles ago. the intake looked pretty good, alot better than some i have seen before!

its building about 22-24psi max boost on a hard pull, and i dont hear any good whistles (much more than over the exhaust, it does have a banks exhaust on it. before saying anything, this has been on the truck for 2 years now, and hasnt had a problem yet, even after the 06E17 that was done earlier. it does have the cat still, only difference i have noticed was it has alot louder whistle, but no driveability issues seen since install). the customer had to have the truck back to run a load of sod this evening, he will be bringing it back so i can finish smoke testing for boost leaks.

as far as i can tell, there isnt any exhaust leaks, but i will check it again. the only thing that i didnt like on installation was how the inlet pipe and the turbo didnt line up right, it took some finesse to get them to clamp together. i did smoke test it when it got put back together, and had no leaks there.

as a side note, this truck has been in to one local dealer about 18 times, towed in about 9 times, driven there the rest. i think there have been about 14 injectors replaced, i gotta go back through the records and see. the original owner was in the middle of a buyback suit with ford, and couldnt afford to wait the time for them to figure out what was going on, so he bought a GMC 5500, and sold this truck off. the new owner has had it about a month now, 3k miles, and it is having the same fits, always a different problem each time.

Jim-thanks for the .pdf's, i have read about them in Bruce's book and online, but never had them as a saved file to reference on my computer. i dont have OASIS, my IDS is on backorder from my supplier, but i gotta make due with what i got for now. i do have ford service DVD's, get new ones every few months, along with several other info sources too. we try to stay as on top of things as ford will allow, but its a whole nother animal in the independent side of things. ford does not want to come off of information, even when we offer to pay for it.

oh well. but thanks again for that set of links.

Jim Warman · July 8, 2006

I'd be concerned about that many injectors.... possibly a fuel pressure issue taking them out?

For te surge... anything that alters the airflow through the engine has the possibility of causing concerns.... may not be evident from the git-go. Other areas you might check....

The MAF sensor (look for the tattle tale "fur coat" with a magnifier). IAT2..... open the EGR valve with active commands and watch IAT2 PID to rise. Map sensor..... chack the hose real close, too. With the abscence of live data, you may be in for a time of it...

This truck does have a stock air filter, right?

Joey Kaylor · July 8, 2006

yep. same powercore thats been in it for about 8k miles.

the only thing i wasnt sure about was the fact the IPR was at 22% at idle. i wasnt so sure what the target should be for it, i know a 7.3 you want no more than about 13%, i was kinda worried that was a little high.

The MAF was cleaned when apart, i usually always to that whenever we get one in for service, as kind of a PM thing. CRC MAF cleaner works damn nice!

the driver is out beating the piss out of it now, i will find out from him tomorrow afternoon how it did. yesterday he told me that the only time it surged was with a 24' gooseneck loaded about 9klbs, i guess now that the clutch is working and they are off their lawsuit kick about the used truck being a lemon they tell me things :rolleyes:

Joey Kaylor · July 10, 2006

jim, thanks again for showing this fatboy those pages, i read over them again today, along with reading through the thread on the recall, and now feel like a retard for not doing that before.

of course, i never saw or heard about the details of the recall till i was on this board, ALLDATA, and MOD only give vague details. being in the independent shops is an uphill battle for service info sometimes! we have to rely on techs that sell the service DVD's on ebay for any real info, unless we want to shell out the copious amounts of cash that ford wants us to for their info.

and people wonder why i am a hardcore follower of the right to repair act?