Black Smoke, EGR & More - HELP!

[charger73fan]

Hello everyone, I recently purchased an '04 250 with 108000 on it. It's been running very well for the 6 weeks I've had it until this weekend. Severe lack of power on takeoff - TONS of black smoke pouring out the exhaust. All gauges run fine, no idiot lights come on. I read another thread in this forum(http://www.superdutydiesel.com/forums/6-0l-powerstroke-engine-drivetrain/12027-power-problem.html) and it sounded much like my problem, so I unplugged the EGR and there was no change. Took it to my local dealer yesterday - they called back and told me today it needs a new EGR valve, new EGR Cooler, new Oil Cooler, and a new intake manifold because all are clogged. The cost was just under 3000. The aftermarket warranty I bought is trying to deny the claim. Any thoughts on a remedy would be helpful considering this is my 1st Ford and 1st diesel, I'm sort of flying blind. Does the diagnosis sound feasible? They listed parts costs as 332.96, 488.17, 702.45, and 436.52 in the order I have listed above. If the aftermarket P.O.S. warranty company denies the claim, is it a do it yourself sort of job? What are your ideas on non-dealer parts? Again, any ideas would be greatly appreciated. Thanks in advance for your time and wisdom!

 

[DaveBen]

First let me say "Welcome to Super Duty Diesel", and then let me say that you can replace the parts your self. I would not replace the intake manifold, but clean it. The EGR Cooler will have to be replaced. You can clean the EGR it self. I don't know why the oil cooler needs to be changed. THis sounds like a typical Ford repair, just keep changing parts until something fixes your problem. Ford NEEDS to teach their techs some other way to FIX trucks.

Dave

 

[charger73fan]

Thanks - I don't understand why the oil cooler needs to be changed either - from what I can understand, it's not a part of the system that's causing me problems. I've already found a couple nice links to EGR cleaning procedures on your site, and the EGR cooler seems relatively straightforward, but how would I go about cleaning the intake manifold? Does it need to be totally removed? If so, it would almost seem like a good idea to replace the thing if I'm gonna go thru all that work. Thanks and I look forward to more advice - I hope I can help you guys out someday myself!

 

[lvtitan]

have you considered an egr delete kit ?

 

[charger73fan]

Nope, please explain - I've never heard of one of these...

 

[charger73fan]

I'm thinking about doing oil cooler, intake, egr valve, and egr cooler myself. Any good websites for cheap parts? Thanks...

 

[BamaSixGun]

I'm thinking about doing oil cooler, intake, egr valve, and egr cooler myself. Any good websites for cheap parts? Thanks...

i have seen some EGR coolers on ebay before.

Like this one EGR & Oil Cooler

EGR cooler only

EGR & Oil cooler

 

[MBRPCrazyford]

THis sounds like a typical Ford repair, just keep changing parts until something fixes your problem. Ford NEEDS to teach their techs some other way to FIX trucks.

Most Mechanics at dealerships aren't Fixers, they're replacers. They don't have to pay for it, so it's easier for them to just replace it. Not everyone is, but some. This is just my experience.