Make sure you do the turbo mount bolts LAST. Keep them in and started, but not tight. I forgot to mention that.

Now when you say you see the smoke, is this smoke still coming out the tail pipe, or do you see smoke under the hood? Usually when it's leaking under the hood it's quite noticeable, it will be loud.

Nothing else changed here? You swapped new turbo on and now you have a ton of black smoke?

You are correct, just one electrical connection to the turbo for the VGT solenoid, and then an oil feed line and oil drain tube... pretty much it. Are you sure all of your intercooler boots connections are tight? Might be worth going through and inspecting those too. They often develop small leaks on the bottom or in other various hard to see/reach places.

Can you hear the turbo at all when you fire it up? How about driving?

 

Hey Mdub707,

Thank you very much for the info. We think we are up and running now. The clamp around the backside of the Turbo coming off the exhaust was an aftermarket clamp from NAPA. It was considerably weaker and possibly a little bit larger and was not clamping the exhaust tightly. We did all as you suggested as well as getting a new clamp from Ford.

We could see exhause residue inside the clamp where it was leaking. We installed the Ford clamp following your instructions and we now have Turbo boost on my gauge and hear the Turbo whine/whistle. Truck seems to be running good. No leaks, or other problems.

Thanks a lot for your input.

Whitey Cook

PS: If you are ever in my area, I owe you some beer and a steak at my home!! Thanks again.

 

 

just read the entire thread and their is great info on this issue here, i have an 05 6.0L PowerStroke with a failing EGR Cooler, has anyone use the BulletProof Diesels full kit that comes with the engine oil system? is this the way to go? i use my truck as a Daily Driver and defenitely to tow, i love my ford but want to make it as reliable as i can as ive replaced the EGR Valve and Cooler in the last 2 year

 

You'll keep replacing them as long as they're there. Where do you live? If you're in a state (California) that tests smog, then you need the bulletproof setup. Personally, I prefer the full delete as it's much less expensive and just eliminates all of it. The Bulletproof stuff is pretty nice though.

Their oil cooler kit looks pretty nice, but $1800? I just bought a new Ford oil cooler rebuild kit for a hair over $200, a coolant flush, this rebuild kit, a coolant filter setup and some new coolant should be all that's needed.

Just my thoughts on it...

 

ohh i feel ya, i know its pricy, just wanted to get input on of anyone has used this full kit and if they feel it was worth the $$$, i just dont want to do this again in 2 years

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Mdub707, so is their another way you made yours work purchasing other components? do you recomend the Bulletproof EGR Cooler? what about their EGR Valve? i know its alot of questions, sorry

 

Yeah, I bought a river city diesel full delete for $185 shipped on ebay, no cooler, no valve on my truck, everything is gone and there is a solid up-pipe in place of the stocker with the scoop. Now I don't have to worry about an EGR cooler failure ever again.

Again, the BPD stuff is nice, and there are certainly enough guys using them, if I had the money to burn I'd buy one, they are a quality piece.

Of course with mine deleted, it would normally throw a check engine light for insufficient EGR flow, (as would your 05) but I already had the tuning to take care of that. My SCT shuts off the EGR function anyways.

The main cause of all these issues is the oil cooler anyways. How about some more info on your truck...

https://www.dieselbombers.com/ford-p...questions.html

 

2005 F250 6.0L PowerStroke
All OEM Equipment, no mods what so ever
2 years ago my EGR Cooler when bad and was replaced by my local Ford Dealer (ChinoHills Ford), they replaced the EGR Cooler and EGR Valve, not the oil cooler
its my Daily Driver, and tow vehicle, i tow my off road Truck to the desert weights 4700lbs average round trip 480miles and i dont tow past 60MPH

 

These things love to work, so don't be afraid to tow with it. That's a relatively light load considering, but enough of a load to give her some what of an exercise. It seems the more these things are used, the longer they last anyways.

How many miles on the truck?

Typically the EGR cooler failure is a direct result of an oil cooler plugging... it'd be nice to know your engine oil temp vs. your engine coolant temp. Have a buddy with a scanner by chance?

I would recommend a coolant filter first, it's $120 and worth it's weight in gold.

 

truck has 130,000 miles on it, i take care of it, i have a scanner, so are the OEM oil coolers good? by adding a coolant filter can it be reletively reliable if i just replace the oil cooler with another OEM one from ford