Keith Browning

WOWEE! /forums/images/%%GRAEMLIN_URL%%/eek.gif TSB 06-19-6 6.0L - MIL ON - P0401, P0402, P0404, P1335, LACK OF POWER, OR SURGE. EGR VALVE CLEANING PROCEDURE. Well if that's not a policy reversal for sure! It makes sense and a lot of owners seem to have been successfully cleaning their valves for a while. The difference is that by the time WE see a valve that needs cleaning, it actually does need cleaning or it's completely clogged up. My only question is what to do with a valve that shows heavy exhaust leaks from the weep holes?

Jim, I am stuck in a transmission class this week and I was told the same. The instructor said December but thought that it would really happen in January. I would say start looking for the course to show up on STARS to get on a waiting list now!

It's probably too late now but I have always assembled and bled the hydraulic system on the bench. I take the slave cylinder and try to fill it before installing and securing the hose. I do remember having to exercise the clutch a lot and at first you may need to pull the pedal up. I have even tried an old master cylinder cap modified with a vacuum port to apply a vacuum to the system to evacuate the air similar to how you would with a P/S system. The key here is patience. Having fought with many of these in the past, we have sold and installed the pre-assembled and purged master, line and slave assembly.

Good luck with the new job!

If you zoom in you will notice that the picture for the MaxxForce7 is the 6.0L. I guess International isn't done with development either. Going by nothing else than what we have seen in the past I am sure that the Power Stroke and The MaxxForce7 will have different numbers. I'm already tired of typing "MaxxForce" - I think I'll start calling it "the 7." As for Ford and what they do, I stopped asking a long time ago.

A really nice PDF document from International landed in my mailbox. This is awesome. An 8Mb PDF titled Clearing The Air that contains info on ULSD fuel, emissions regulations, after treatment, MaxxForce Engines and engine production. ClearingtheAir.pdf

Do you mean that you hope they are finished in time for the fair or that you hope that they don't break down on the way? /forums/images/%%GRAEMLIN_URL%%/shrug.gif Sorry if I sound cynical but that's all you seem to read right now with little official information circulating.

The last line of your signature says it well. Quote: "Customer expectations exceed design limits." After we get done laughing about that we might think about just how true that is. You might try hinting to the guy that he should consider going 1 class higher in truck next time around. Until then, I have read that head studs and fire rings are effective but I have no experience. Of course you realize that once you, your dealer and the customer agree to go that route you own it.

Anyone going? Bring a camera! /forums/images/%%GRAEMLIN_URL%%/thumbup.gif

Was there any carbon between the lower fuel o-ring and the copper seal that would indicate combustion leaking past the seal into the injector? A short time ago I took over a job for a co-worker that kept blowing injector #2. Three injectors went into the truck before I got it. I suspected that the injector sleeve was distorted from the original failed injector. Replaced the sleeve and the truck has not been back. ... just another idea.

YES! I would like to know the workaround if you could. I just want to see the difference between the two tests.

When I first attempted to run the test it not only aborted due to the neutral switch but as you mentioned, engine temperature. I just could not determine what was going on with that switch signal. It has an Allison MD series trans and there is no indication of a problem relating to the switch. I am not going to lose sleep over it as I was able to diag the rough idle to the point that I know it's somebody else's job now. I will be sure to ask many questions when I go to "school!" /forums/images/%%GRAEMLIN_URL%%/notworthy.gif

Funny you should resurrect this thread today. I brought in a new F750 with a C7 ACERT engine running very rough at idle, no MIL and no codes at all. This was only the second time I really got to play around with the ET software. Anyway, I used the cylinder cancel test and identified cylinder #4 as the low contributor. Probably an injector - that said it's going to have to go to our local CAT service center because I am not authorized to do internal work. I do have a question though. There were two different cylinder cancel tests. One worked and the other aborted because "test conditions were not correct." There was a message about the transmission neutral switch not being on. /forums/images/%%GRAEMLIN_URL%%/shrug.gif I put the shifter in both park and neutral but I got the same result. Does anybody know what thats all about? And later this month I get to go to CAT for a re-cert on the familiarization. Whoop-tee-doo! But I am also signed up for a course on the ACERT engine itself. Perhaps then I might get to actually perform repairs? We shall see! I don't see too many CAT engines in with problems but it's nice to be armed and capable. This also doesn't allow me to get to know the software either.

/forums/images/%%GRAEMLIN_URL%%/smirk.gif Maybe we should format your post and paste it in th thread... Where did that come from anyway? We should post it.

Our dealer had this van drop shipped at Quigley to have a 4X4 system installed and was waiting it's turn when we sold it to someone that wanted it as is. (or was) So we sent a driver to go get it and it over heated. It never made it to the dealer where the PDI was to be performed. The van is sold and was to be delivered that evening. Hey, now would be a great time to apply undercoating! /forums/images/%%GRAEMLIN_URL%%/smirk.gif

Seeing is believing, I removed far fewer parts than when I do the same thing to a Super Duty. This was also a lot cleaner and neater but it is much tighter so getting everything back on right and tucked in securely is very important.

/forums/images/%%GRAEMLIN_URL%%/rockon.gif I raised the van completely off the frame this morning and it was really easy. It took me a little longer because I had to determine what needed to be disconnected. Keep in mind that this is a stripped cargo van with no rear seats or trim. Only a plastic mat had to raised to access the body mount bolts. Who cares about beating the book time (like that could happen with a DIESEL VAN) I'm liking the fact that this engine swap won't be aggravating or piss me off and take weeks to complete. Anyway, I thought I would report that it can be done and it is worth the effort. Should I document the process?

Quote: Diesel maker plans 417 layoffs Automaker Ford's woes have ripple effect on Powerstroke supplier International Truck. In the 23 years since Joe Dobson came to Indianapolis to work on International Truck's engine line, he could count on one sure thing. Every year, Ford sold more diesel pickup trucks. And every year, Dobson's engine line made more diesels for Ford. Now that certainty is fading as Ford is struggling. On Oct. 2, about a third of Dobson's co-workers will be laid off when International Truck and Engine, based in Melrose Park, Ill., idles 417 of its 1,100 local employees, the company said Monday. In a sign of the slowing truck market, the workers may not be recalled until January. Even that recall will depend on whether Ford has sufficient orders for its diesel-powered pickup trucks. "The diesel business has just been going great until this year. We haven't really had a layoff like this for 20 years," said Dobson, 60, Lawrence, formerly of Illinois. He works on the assembly line turning out the plant's only product, a 6-liter diesel used only in Ford heavy-duty F-series pickups. International Truck, part of Navistar International of Warrenville, Ill., has been a steady employer in Indianapolis ever since Navistar predecessor International Harvester signed a plant-saving agreement in 1983. That deal converted the factory to diesel engines and promised to supply Ford pickups exclusively. Since then, Ford has bought more than 1 million of the diesels, marketing them as the Power Stroke brand. The agreement continues through 2012. But just as Ford this month started to promote a larger 6.4-liter Power Stroke to be made in Indianapolis next year, high gas prices eroded the pickup market. Cash-strapped Ford stumbled. International already had scheduled three weeks of late-summer downtime to accommodate slumping Ford orders. Then, Ford suddenly decided to cut fourth-quarter auto production 21 percent to avoid paying heavy consumer incentives to keep sales rolling. Now, International intends to lay off what amounts to an entire shift until orders rebound from its only customer, Ford's Kentucky Truck plant at Louisville. It'll be International's largest layoff since 350 were temporarily idled in 2002. In Indianapolis, plans call for layoffs of 380 workers represented by the United Auto Workers and another 37 nonunion and white-collar workers. "This is being driven by truck production cuts at Ford," International spokesman Anthony Page said. "When we call people back, it'll be based on demand for the new engine. "International's Eastside foundry, the 550-employee International Casting, will continue operations without layoffs. It supplies International diesel plants in Indianapolis, Melrose Park and Huntsville, Ala. PLANT AT A GLANCE [*]Name: International Truck and Engine Corp. [*]Address: 5565 Brookville Road, Indianapolis. [*]Employees: 1,700. [*]Average hourly wage (salary and hourly combined): $28.83. [*]Produces: Ford Power Stroke 6-liter diesels. [*]Company headquarters: Melrose Park, Ill. [*]Owned by: Navistar International, Warrenville, Ill. Copyright 2006 IndyStar.com. All rights reserved

And I suspect that happens more than you might think. Plus I have a voucher somewhere for that $50 or $100 Ford sent us for being good little diesel techs. I recall you had to go on-line and claim it or something like that... misplaced my voucher I think... don't remember where I...

Good find but have you ordered any? I am afraid to until I know for sure that this product is what we are looking for. My parts department has been screwing up real bad lately and some guys have been letting them know how they feel... I don't want to ask them to order these and then tell them to send it back! /forums/images/%%GRAEMLIN_URL%%/shocked.gif But then again, that would not even come close to the "extra" DOES II line engine they ordered by mistake! /forums/images/%%GRAEMLIN_URL%%/eek.gif

Don't-cha hate that? With all the problems you had the first go around perhaps you were rewarded with all you learned from that experience.

Nah! Most people fear a change even if where they are is bad. It sounds like the commute is whats holding you back. The new place you describe sounds a lot like where I am. We have several guys that commute from Pennsylvania- an hour away. I guess it's worth it to them.

It's official, a line engine was approved and has been ordered. Anyone lift a van body before? Any advice or hidden things to look out for? Maybe I should document this one.

Damn the luck. Just when you get all the iron and the headaches done somebody goes and severely overheats a diesel van. Melted oil stand pipe, metal in oil filter housing, oil smells NASTY /forums/images/%%GRAEMLIN_URL%%/eek.gif and only 150 miles on the clock. I found the lower radiator hose had folded under along the bottom edge and was caught under the clamp area. The result was coolant spraying under pressure every time the engine torqued. I guess now I get to learn raising a van body off the frame. At least it's a stripped cargo van!

I was discussing this with someone and for some reason we were thinking that once upon a time 3M made a 1" disk. The more I think about it the more clouded my thoughts get. Does anyone know if they did or not? /forums/images/%%GRAEMLIN_URL%%/shrug.gif Quote: Originally posted by Scott B.:I have some old gasket punches that a Pre cut a Bunch of Pads down to size with so I dont have to mess around trimming them up.Helps a little anyways Awesome idea! I love multi-tasking tool ideas. /forums/images/%%GRAEMLIN_URL%%/thumbup.gif