Ford Doctor
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Everything posted by Ford Doctor
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From the album: Electrical Problems
These glow plugs from a 6.0L Power Stroke diesel engine tell a grim story. Removed to perform a manual compression test they are the result of a failed turbocharger that leaked a lot of oil into the charge air cooler. The oil is drawn onto the engine where it causes pistons and glow plugs to melt. The engine these came from actually "ran way" resulting in no compression in three cylinders.© Keith Browning
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From the album: Electrical Problems
Harness chafing on a 6.4L Power Stroke diesel engine. This is the take out for the high pressure fuel pump near the glow plug control module. The wires rubbed through on the heat shield that covers the GPCM causing a driveability concern and a check engine light.© Keith Browning
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From the album: Electrical Problems
I always thought "bad wiring splices" were a mythical failure dreamed up Ford as an example or for writing up warranty repairs. It took me 22 years to finally come face to face with one. If you look closely you can see the darkened areas where arcing occurred.© Keith Browning
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From the album: Electrical Problems
This Intake Air Temperature sensor (IAT2) is carbon fouled. It is recommended that this sensor be removed and cleaned any time a 6.0L Power Stroke engine that has EGR text problems is serviced.© Keith Browning
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From the album: Electrical Problems
These Camshaft Position sensors from 6.0L Power Strioke diesel engine show what happens when an engine block rusts under the sensor and pushes it slightly out of the block. This creates weak CKP signals and no start conditions. Technicians skilled in using an oscilloscope can easily diagnose this. If you cant see it, the sensor on the left is bent at the mounting base up top.© Keith Browning
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From the album: Electrical Problems
It is vitally important to ensure that wiring and connectors remain properly secured to prevent damage. This exhaust gas temperature sensor EGT13 harness was found laying on the diesel particulate filter (DPF) damaging it© Keith Browning
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From the album: Electrical Problems
Crankshaft position sensors rarely fail but the o-rings that seal them to the engine do leak sometimes. The sensors are difficult to remove sometimes due to sticking and can easily break in the process. We thought it would be neat to show what is inside. These are usually not easy to get to much less remove.© Keith Browning
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From the album: Electrical Problems
6.0L Fuel Injection Control Module (FICM) failures are a well known pattern failure. It is now common to repair the modules by replacing half of the assembly and rarely is there any visible sign. Here is one that did show burnt electronics on a circuit board.© Keith Browning
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From the album: Electrical Problems
Here is the fuel heater removed from an Econoline fuel conditioning module (DFCM). Rust from the fuel tank has collected on top of this heater eventually causing the PCM fuse to open creating a no start condition. This was not an easy one to diagnose and nail the root cause.© Keith Browning
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From the album: Electrical Problems
Looking inside this fuel filter housing from a 7.3L Power Stroke engine we can see the fuel heater element anchor points have corroded and allowed the heater element to loosen. This failure is common and can cause a no-start condition due to a blown fuse.© Keith Browning
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From the album: Electrical Problems
This ICP harness pigtail was connected to the sensor in the previous image. The oil that leaks from the sensor travels through the wire and causes the insulation to soften and swell often causing exposed wire© Keith Browning
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From the album: Electrical Problems
An ICP sensor from an early 2003 6.0L Power Stroke engine that has failed in a big way. It is common for this sensor to physically separate and leak oil in the process. Often driveability concerns like surging, stalling and lack of power occur as well.© Keith Browning
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From the album: Air Management Failures
This is a vane from a 6.0L variable geometry turbocharger. Observe the wear at the tab that mates with the unison ring which is fairly rare. This wear is also caused by corroded and binding parts. The resulting drivability concern would likely be low boost and or surging.© Keith Browning
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From the album: Air Management Failures
This VGT actuator likely failed due to a lack of maintenance. The oil passages show a lot of crusty and abrasive burnt oil residue. This proves there is more than one way to render a turbocharger useless by neglecting maintenance. This is not a common failure.© Keith Browning
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From the album: Air Management Failures
The EGR valves in 6.4L Power Stroke engines are typically seized in the intake elbow. When the puller specifically designed to remove the valve fails to do so either the tool or the valve breaks. This time the tool won.© Keith Browning
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From the album: Air Management Failures
This Diesel Particulate Filter was bolted to the DOC in the previous image. It too is beyond service and requires replacement.© Keith Browning
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From the album: Air Management Failures
A poorly maintained 6.4L Power Stroke diesel engine led to a failed turbocharger that leaked a significant amount of engine oil into the exhaust system where it pooled inside of the diesel oxidation catalyst. At this point the DOC is beyond servicing and must be replaced© Keith Browning
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From the album: Air Management Failures
Black sooty tail pipes on any diesel truck equipped with a Diesel Particulate Filter (DPF) indicates that the DPF has failed. If the filter isn't trapping soot it isn't doing it's job.© Keith Browning
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From the album: Air Management Failures
This is a catalytic converter from a 7.3L Power Stroke diesel that has broken up When the pieces move around inside the converter they can literally block off the outlet effectively increasing exhaust back pressure causing low power.© Keith Browning
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From the album: Air Management Failures
This 6.0L Power Stroke diesel charge air cooler has split at the end tank seam. Most of the time they won't separate this wide but rather loosen enough to just blow out the seal© Keith Browning
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From the album: Air Management Failures
There is a torque spec for the CAC tube clamps for a reason. Over tightening the clamps can pinch and cut the tubes. This is more common with an aging tube that has softened and degraded.© Keith Browning
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From the album: Air Management Failures
When inspecting the charge air components it is advisable to clean off dirt covered charge air cooler tube connector hoses to inspect for cracking and other perforations.© Keith Browning
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From the album: Air Management Failures
Air filter housings and inlet tubes need to be kept in good condition, be properly assembled and checked for leaks at any ribbing or pleats. Wear and damage to the turbocharger compressor wheel will result if the air intake system is compromised.© Keith Browning
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From the album: Air Management Failures
This perfect example of a worn unison ring control slot shows it's relation to the control arm. The gap results in a surge under loaded conditions.© Keith Browning
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From the album: Air Management Failures
Yes, it is broken for sure. The vane pinions are not flimsy therefore we can only assume that a casting weakness existed or foreign material like the piece of casting we found in the turbo had something to do with the demise of this turbocharger. The casting piece (not pictured) looked like it most likely came from one of the manifolds.© Keith Browning
