2005 6.0 diesel with 88,000 miles, I use for light hauling.
I just replaced the EGR cooler due to radiator fluid turning brown and truck smoking and a fuel injector (due to breaking off plastic connector) and put the motor back together. I started the motor and let it run for 10 minutes to check all connections and wiring. Everything checked out fine. Motor ran smooth with easy spool up. I then took it down the road and when I got up to 60mph with 15-20psi of boost the motor turned off and white smoke came out of the exhaust. I was able to start it but it was like having a fog machine and the motor began running rough and died. I was not able to restart the engine again. After trying for a while the batteries appeared dead. I recharged the batteries but they would not turn over the motor and the motor would only do the click click click sound. I rechecked the batteries with a load tester and they both were well charged. I need help on this thing. I am tired of it being a lawn ornament. What the @#$ is wrong? Thanks in advance.

 

So you replaced the EGR cooler which I'm guessing was blown? Did you replace anything else? Oil cooler should have been replaced which is what probably caused the EGR cooler to fail in the first place. If that wasn't replaced, you probably just popped another egr cooler, which is where the white smoke is coming from and my guess is that it is now hydrolocked.

Were the headgaskets done or anything else? How did you come to the conclusion the EGR cooler needed to be replaced? Who is doing the work on it, you or a dealer or...?

 

I did the replacement. I changed out the oil cooler, replaced all EGR, Turbo oil line gaskets, o rings and head gaskets. The EGR was replaced due to puffs of white smoke and the radiator fluid was turning brown.

 

Who did the headwork? Heads were decked/magnafluxed? Typically the ONLY way the oil and antifreeze mix on the 6.0's is if the heads are cracked. If they were never brought to a machine shop, then I think you found your problem.

 

I wrote wrong. I replaced the intake manifold gasket not the head gasket.

 

Ok, refer back to my first post now.

 

Well I pulled out the glow plug on the injector I changed and cranked the motor. Large amount of fuel came out. I tried to crank it again and the motor wouldn't crank. I pulled all the glow plugs off the passenger side bank since they were on the side of the replaced injector. The motor will still not crank over. Will try to hand crank motor with wrench and see what happens.

 

Pull ALL of the glow plugs and try cranking. You know it's fuel in there or is it coolant coming out?

 

It definitely smells of fuel

 

Well pulled the glow plugs and only the new injector was the one acting up. I pulled the injector and it had a broke o ring. Fixed it now the truck runs but is blowing smoke out the back that smells like oil. Damn truck. I had a guy who I thought knew about trucks and he sprayed carb cleaner in the turbo he said because the vains were dirty. This was prior to putting it back together. By him doing this did it jack up the turbo?

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Went out to the truck and let it run a while to check the turbo. The smoking is almost non existant but I did find I have an exhaust leak behind the turbo. While running the motor the engine light came on so when I checked it is says low fuel injector pressure. Does anyone know how to fix this?