2006 F350 6.0 CEL On. No Power. Blowing Huge White Smoke.
 

96k miles on 2006 F350 with infamous 6.0 No mods besides 4 inch straight exhaust. No after market gauges. Has not overheated. Haven't noticed the two factory temp gauges go any higher then normal. I've got maybe 3000 miles on truck so far. Oil level fine. Coolant level fine. No water in oil. No raw fuel out of exhaust. No oil in coolant. No visible leaks. BUT have smelled coolant for last couple weeks after truck has been running. Not inside truck. More around front of truck engine compartment. That has me stumped!

Last night I drove truck about 10 miles in mid 40 degree weather. Parked it for about 35 minutes and when I restarted it and left up the hill it felt like it was missing some power when I put my foot in it. Have noticed this when it is cold for last couple weeks. Almost like 1/2 power till it warms up. Almost feels like there is a governor on it when cold driving.

I stopped at an intersection and truck lost all power, started missing and check engine light came on. (not wrench light) I noticed a LOT of white smoke cloud. (it was dark out) I pulled truck forward on level ground and turned it off and restarted. Same issues. I was a mile from home and limped down the level road at little better than idle and it still left intermittent white clouds of smoke when I tried to accelerate. About 1/2 mile later the sputter flattened out and truck regained power. Able to drive it up steep hill with no problem. This morning I started it (has been hard to start in the mornings 5 second starts with blue smoke for a few seconds) noticed it had constant light white smoke. Smelled rich. Burned eyes.

I pulled the EGR valve and it was CAKED in soot! Noticed inside manifold was TOTALLY caked around side openings) I cleaned the EGR and oiled it and put back in truck. Drove fine. No smoke. Just scanned it and 3 codes. P0403, P0404 and P405 all pertaining to ERG. I cleared the codes and unplugged the EGR. Seems like there is more power. But I'm worried that might not be the real issue here.

I've recently noticed: smell of coolant around the truck. Cant identify any leaks and have NOT lost any level. Cant see any wetness anywhere. I did look in manifold when EGR was out and didn't notice and moisture. Fuel economy has sucked since I bought this truck. Only other issue I've had is it developed a no start hot condition. Ford told me $2k to fix and after I got it out of there it stopped all together and became harder to start cold then hot if anything. Weird! I've read many forums but can't pin point any predictable causes or remedies. Is the smell of coolant likely my EGR Cooler beginning to fail? Could it be just the EGR valve? Anything else to look for before something catastrophic happens (which I can't afford) Appreciate ANY insight! Thanks!

Being new to the 6.0 myself, I just looked over the service bulletins for some issues of my own. I did find this one.

Cold Temperature Lack of Power, Poor Economy, Hard Start, Excessive White Smoke, or Coking (carboning) of Turbo, EGR System or EBP:
This could be due to gelling of the fuel, formation of ice in the fuel tanks or lines or poor fuel quality. If diagnosis finds no cause for the above symptoms, try using a fuel conditioner, such as Stanadyne Performance Formula or equivalent, such as Motorcraft PM-22-A or -B (cetane boost), or PM-23-A or -B (anti-gell/cetane boost), that will improve the cetane level and lower the gell point of the fuel. Do not use any product containing alcohol. If the conditions improve with the additive, then find another fuel source or continue to treat the fuel. Broadcast Message 1309, 1464, 5113, 6875; SSM #17406.

It may not apply to you, but it's a place to start. Good Luck..