DamageINC Posted April 14, 2008 Share Posted April 14, 2008 Ok friends, here's my current situation. '04 F-350, 150k miles, local paving company owns the truck and a bunch of others from us as well. EXCELLENT customers, does all their maintnance with us, so on... either way, they came in complaining of black smoke intermittently and erratic power loss. P0404 in memory and nothing else.. Yank the EGR valve out and it's totally carboned through and literally dripping with coolant. Turbo was replaced about 3 months ago. Toss the valve in and drive it, found an ECT/EOT difference of over 30 degrees. So, I sell them an EGR valve, and EGR/OIL coolers, and a heavy intake cleaning. After some down-time, they decided to put the money into the truck. I replace the coolers and the valve, start it up, it runs like garbage for about 30 seconds and then dies. Won't start. ICP maxes out at 85psi...wonderful. Turns out that the IPR blew apart, due to the HPOP eating itself up too (the screen was shredded and there was debris all over it.) This is the OLD STYLE HPOP too with the cast iron cover. Either way, I feel terrible about bashing these guys over the head with another big-dollar repair right after they just bought the coolers but it just won't leave the shop without the parts. They buy it. I install it (HPOP and IPR), start it up, runs like a champ. Drove a TON better than it has in years, probably. After driving it, I let it idle for a while and then parked it behind the shop on Saturday. I come in today (Monday morning) for one more drive on it, and it doesn't start. ICP maxing out at about 115psi, won't go any higher. I'm not really sure how much more shit and I wanna hammer these guys with and I'm afraid they're gonna thing we're hacking it over here, now that they've bought all this stuff and the truck still won't run. Either way I'm gonna air-check the high-pressure oil system for leaks but, my question is, has anyone here dealt with a similar scenario like this? What'd you find? Dave Quote Link to comment Share on other sites More sharing options...
snw blue by you Posted April 14, 2008 Share Posted April 14, 2008 I feel your pain! Good luck, I'm sure you will be able to sell it to your customer and salvage the relationship. Have faith brother. Quote Link to comment Share on other sites More sharing options...
Jeff_E Posted April 14, 2008 Share Posted April 14, 2008 Um... actually I have heard of things like this. It seems a lot of people are having high pressure pump failures due to contaminated new oil coolers. The factory which builds the cooler housing, first makes a mold out of a sand/oil mixture, then they dust the mold with a white flashing powder prior to pouring the aluminum...this allows for easy separation of the mold once the cast is finished. They apparently just break the mold off and call it good, rather than cleaning the residual powder from the casting process. Most of the new oil coolers that I have replaced, still had the white powder residue stuck to the underside which can be cleaned with brake cleaner and your finger. If left in the cooler, this stuff will shred high pressure pumps, and causes all kinds of pain. If you end up finding this to be the root cause, hopefully you can get Ford assistance on it. I feel for you buddy /forums/images/%%GRAEMLIN_URL%%/crybaby2.gif It's things like this that inspired my high school shop teacher to come up with the brilliant line that I am currently using for a signature. Ahhh, Mr. Frye... Those were the good old days, back when I was surrounded by women my age, and didn't have a mortgage!!! Quote Link to comment Share on other sites More sharing options...
DamageINC Posted April 14, 2008 Author Share Posted April 14, 2008 Actually Jeff - wow! Just because I was going to air test the system, I yanked the turbo and, on a whim, took the IPR out to look at it. Brand new IPR, screen has a hole blown clean through it and inward, kibble all over what's left of the screen. Initially I thought that the new HPOP was bad out of the box and had taken the new IPR out as well, but now that you mention this, I have some more head scratching to do! I'm gonna buzz the ol' hotline real quick and see if they by some miracle have anything useful to say about it, but that's a great pic and I really wish I'd thought to look at the oil cooler BEFORE installing it on the truck. Either way, SPW repair, here I come! I'll keep you guys posted with what happens, but keep the other ideas coming too. And thanks for the great pic, Jeff.. Dave Quote Link to comment Share on other sites More sharing options...
Tony302600 Posted April 14, 2008 Share Posted April 14, 2008 Dave, when you did the oil cooler you should have checked that screen in the block. When an oil cooler is done, i suck out all the oil and check the screen in to the block to make sure there isn't any shit sitting in the bottom of the galley. A must according to hotline!!! Quote Link to comment Share on other sites More sharing options...
DamageINC Posted April 15, 2008 Author Share Posted April 15, 2008 I always check that screen, of course!! There was *nothing* on it or beneath it, I always dry up as much oil as I can and check the screen, clean gunk out of the resivoir, and fill it with fresh oil before installing the new cooler. Hotline told me to replace the oil cooler, HPOP, IPR, and the screen again as an SPW repair. Whoopee!!! Dave Quote Link to comment Share on other sites More sharing options...
eastendpowerstroke Posted April 15, 2008 Share Posted April 15, 2008 well at least you got paid the CP labor to fix it the first time, after you get the Warranty labor to SPW it you may break even.... /forums/images/%%GRAEMLIN_URL%%/rofl.gif Quote Link to comment Share on other sites More sharing options...
DamageINC Posted April 16, 2008 Author Share Posted April 16, 2008 LOL I said that to my SA right after I found out I was SPW-ing it and he just glared at me... Dave Quote Link to comment Share on other sites More sharing options...
DamageINC Posted April 17, 2008 Author Share Posted April 17, 2008 Well just so you all know, the new oil cooler I got was *loaded* with that powdery crap, it was seriously caked onto the side of it pretty thick. I took it to the parts washer and got all the crap out of there. I'm amazed that this powder can create such havoc, though, I'd imagine that it'd almost just dissolve in the oil, it's so fine. Either way, the new cooler, IPR, HPOP and screen definitely took care of the problem. Again. Dave Quote Link to comment Share on other sites More sharing options...
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