My 03 X is in the shop right now for a bad turbo. Starting making a horrendous metallic slamming noise while pulling a 10k load, then loss of power, etc. I'd pull over on the interstate, let it cool down, restart the engine, and it'd be fine. FYI, without a load, the truck would run fine.
Ford said that the turbo wasn't cooling down properly, so under heavy load it'd overheat. They ordered a new turbo (4-5 day wait on a rush order) and installed it this past Tuesday. However, the new (remanufactured) turbo was leaking oil pretty bad, so they ordered another one. Another 4-5 day wait (service manager acknowledged the problems with 03 6.0 turbos and said Ford can't keep them stocked on the shelf). New (again, remanufactured) turbo came yesterday and they installed it. I was told they test drove it and it put out 24 psi of boost according to my X-Monitor. However, when I picked up the truck last night, I pulled off the lot and the turbo wouldn't spin up at all, wouldn't get over .3 psi of boost. Turned around and caught the service manager and mechanic (it was 6 pm at the time--closing time). They stayed, along with two other mechanics and me, in the bays until 10 pm trying to fix it. They'd rev it up and blue smoke would pour out of the engine, but it was so heavy they couldn't see where it was coming from--it did get progressively worse as the night wore on. They checked the turbo front and back, the intercooler front and back, and the exhaust for obstructions but it was all working as it should. The turbo was apparently working as it should, spinning without a problem (sorry, don't know the technical names for all the turbo parts).
Well, it was obvious that the problem wasn't a quick fix so the service manager said it'd have to wait until after Memorial Day when they could call the Ford hotline. They're not convinced the turbo is bad, but it may well be.
All this is covered under the warranty, but I'm apprehensive about what'll happen at 100,001 miles. The current problem seems pretty involved with both the turbo and the motor. Prior to this, the only problems I've had with the motor are two bad injectors that were replaced before the truck had 10k on the clock. Should I be apprehensive?
BTW, I've got a SCMT but tow on stock or on Tow Safe, and never set it above Tow Safe, even when not towing. I want this to be a 200k mile truck so I take it easy on the motor.
