I have just has the turbo rebuilt on my 2004 6.0 L powerstoke and have a bad exhust leak around the exhust to turbo inlet & tail pipe to turbo connection. This is causing a lot of exhust fumes in the cab,I have replaced the exhaust clamps with new ones and taken the thing apart and carefully put it back together 3 times. I am running out of ideas and wondered if anyone has any experience with this problem. Its my first diesel and I am just about ready to torch the piece of S**t.

 

calm down and breath .........................welcome to the site bud

I dunno nuttin bout any Fords but we have some here that do...........................they will be along shortly

 

Thanks for replyin ol man, I am getting frustrated with the ford I have only had it 3 months and its spent most of its time in my shop. Looks like I will have to admit to my ol lady I did buy a pup after all.

 

thats what you get for buying a 6.0h no

 

TTT.....................someone help here please

 

is the clamp on the turbo to exhaust pipe lined up and seated right

 

I have installed new clamps and used a mirror to look around back to check if they are seated ok, I also left the connections to the manifolds and down tube loose and tightened last but to no avail. I took the truck to ford to get a diagnostics test done they said the exhaust is all plumbed up wrong? I can see there is only one way this thing will fit you could not make it fit any way exept the way it is and they wanted $383 plus taxes to take the exhaust off and re fit. (i don't think so)

 

So who put the exhaust on? If they say its not plumb per say i take that as the sections are pipe are not in the right orientation with each other and they are twisted/stressing on the connection at the turbo. If thats true, loosen everything up and try bolting the down pipe on by itself and go from there.

 

maybe get a new down pipe and try that with a new flange

 

Thanks for the input guys, I was thinkin along the same lines with the flanges not being in line & stressing, the down pipes and turbo inlet pipe look ok but after three attampts at sealing them I may be looking at buying new parts. I don't want to give in to the Ford dealership I have been fixin my own motorbikes, cars & trucks for 25 years but this powerstroke exhaust has been one of the most frustrating yet I'll let you know how I make out.