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-   -   $9,000.00 dealer estimate (https://www.dieselbombers.com/ford-powerstroke-03-07-6-0l/93712-9-000-00-dealer-estimate.html)

olbattlebuggy 03-29-2012 07:49 PM

$9,000.00 dealer estimate
 
I have a 2004 excursion powerstroke. I have been having some cold start issues and white smoke after a acceleration to coast. im running a Banks IQ on economy setting. high flow intake with industrial injection stage 2 turbo and turbo back 4" exhaust. I had the dealer do a diagnostic and the mechanic report was " entire Left bank injectors failed and the right bank of injectors are on verge of going. EGR frozen and needs replaced. remove and clean intake manifold replace all 8 injectors clean turbo repair/replace coolant hose to HP oil cooler that has been leaking, oh yah forgot he also needed to reflash FICM after replacing injecters." wants 9 grand for parts and labor.
When I run a code check on my Banks IQ the only code I get is #6 injector out of balance. EGR inop and crank pos sensor. on occasion ill get a zero read on back preasure value.
I asked if their was any possibility the harness could be bad as i thought that all the wires for these sensors are in the same loom. The service manager said to let the professionals handle the diagnosis. What a TOOL.:argh:
The truck seems to run fine when warm weather but problematic when colder out.. any suggestions would be greatly appreciated.

bobfbigman 03-29-2012 07:55 PM

WHen all of the sudden all the injectors aren't right then its probably NOT the injectors. Test you FICM first, its on top of the driver's side valve cover, that is what controls the injectors.
http://www.bscustoms.net/diesel/FICM.pdf

olbattlebuggy 03-29-2012 07:58 PM

reply;reply
 

Originally Posted by bobfbigman (Post 877293)
WHen all of the sudden all the injectors aren't right then its probably NOT the injectors. Test you FICM first, its on top of the driver's side valve cover, that is what controls the injectors.
http://www.bscustoms.net/diesel/FICM.pdf

thanks bobf...
i grabbed my dig multimeter yesterday and plan on testing SAT.. Do you think the harness might be frayed or am i thinking to much?

bobfbigman 03-29-2012 08:14 PM

Always a possability, look for chaffing too, if it tests OK go ahead and remove it and look at the harness right under the plugs where there is a tight bend, they tend to wear there and anyplace they are pulled tight or pinched under the intake tubing. That dealer is on CRACK, I can buy a nice truck with that kind of money. What area are you in???

Ltk 03-29-2012 08:59 PM

you should tell "professionals" at the dealership that he is a MORON. you could replace the WHOLE engine with a brand new one, with everything needed for $9000...

definitely dont let the dealers take this into their hands. i got charged a HUGE price to "replace and reflash computer" which Mdub707 can do for you if you give him a message.

dont let the dealer screw you on this one. the people on here can help you better and much cheaper than any dealer or shop can.

tiremann9669 03-29-2012 11:24 PM


Originally Posted by Ltk (Post 877339)
you should tell "professionals" at the dealership that he is a MORON. you could replace the WHOLE engine with a brand new one, with everything needed for $9000...

definitely dont let the dealers take this into their hands. i got charged a HUGE price to "replace and reflash computer" which Mdub707 can do for you if you give him a message.

dont let the dealer screw you on this one. the people on here can help you better and much cheaper than any dealer or shop can.

I'm kinda doubting there are any professionals there :w2:

olbattlebuggy 03-30-2012 10:12 AM

Thanks Guys for the replies....
I'm in Cleveland Ohio.. West side area if anybody is local and wants to get in touch with tech help feel free to PM... Oh and I did mention to the Service manager about dropping in a fresh rebuilt for less,his reply was then you should go do that.. What a TOOL...

J HO 22 03-30-2012 11:19 AM

9,000.00 is crazy!!!

1999stroker 03-30-2012 12:15 PM

To the op I live above cincy, my suggestion would be try a different dealer.


Strokin' Away

Mdub707 03-30-2012 02:20 PM

That's a terrible diagnosis. That stuff could be easily fixed for far less. For $9k they didn't even include a headgakset job on that? They're doing almost nothing for that money. You could buy me a plane ticket to fly out there and buy me all the tools I would need to fix it, and the parts, and fly me back home for probably less than 1/2 of what they quoted you, and even that would be stupidly absurd. :argh:


Truck could probably use a coolant flush, a coolant filter, a oil cooler rebuild, and EGR delete, and a FICM rebuild to run like a top again. Depending on mileage, may need an injector or two, but none of that is anything someone with basic tools couldn't do in a weekend...

olbattlebuggy 04-01-2012 03:11 PM

Q
 
Whats the difference between the blue and Green HPOP spring upgrade? I'm making my parts list on this repair and might as well go all the way...

Mdub707 I sent you an e-mail with a Q? couldn't PM due to lack of posts:dang:

Mdub707 04-01-2012 06:40 PM

I will check that out tomorrow bud. Been a long weekend and I do most of my DB work when I'm at my real job.

The "blue spring" upgrade is for fuel pressure, nothing to do with the HPOP. The blue spring is the "update"... the green is what is in there already. I'll get you a P/N tomorrow for just the spring/o-ring.

Post up what you have for a parts list now, and I'll add to it for you or see what you have. :c:

olbattlebuggy 04-01-2012 07:47 PM

currently got
 
my current list of mods are as follows:
4" turbo back exhaust from MBRP
Stage 2 Turbo form Industrial Injection
SnB Cold air intake
Banks 6gun tuner with IQ interface(soon to be replaced)


I know that my#6 injector is bad so off the top of my PSD comes
gotta have FICM reflashed due to Ford dealer crummy flash fix(11mpg)
sinister delete for the EGR and a new cooler with the Kit.
Flushing cooling system and installing remote filter kit With the blue spring upgrade to boost the fuel preasure.
Due for Filters and oil change so i have some rev-X on the way for both fuel and oil.
have some 15w40 Royal Purple in stock that I caught on sale so in it goes with the rev-X
since the air intake has to come off any way I'm gonna have it Hot dip cleaned to remove all that built up EGR soot. Since the turbo is off the truck anyway I will service/clean as well. I know the turbo is new stage 2 industrial injection I bought it last year. Gonna replace the turbo return line that Im sure has not been updated with the turbo swap.
replace #6 injector and reassemble. hopefully she will purr like a kitten at Idle and roar like a lion when stomped. I think im gonna do the Amsoil remote 1micron bypass oil filter as well. I Have an Excursion so I don't have the luxury of popping my cab off to do the head studs:dang:.
As far as the Banks six gun tuner with the IQ goes its off to ebay for a new home. i am changing to a SCT live wire with custom tune to reflect the upgrades...

Keep fingers crossed....Here...WE...GO!

Mdub707 04-02-2012 09:59 AM

Here's the PN for the blue spring: 6E7Z-9C165-B

The sinsiter EGR delete doesn't come with any cooler, that's the whole point, to get rid of the cooler. You probably meant new up-pipe.

Also I wouldn't waste my money @ Ford getting the FICM reflashed, shoot a message or phone call to Bill @ PHP (power hungry performance) and talk to him about a FICM rollback. He can get some of the older programming on there for you and get the mileage/power back.

I'm also not a fan of royal purple at all, but I guess that is more personal preference than anything.

When you get custom tunes, be sure to tell them what turbo you're running too, so they can write the tunes for it.

Also, you COULD pull the cab off of the X too. It's only a couple more bolts, the fuel filler neck and the tail light plugs... it's really not that much more work than it is over a truck, just FYI. :w2:

If you need any other Ford P/N's let me know.

Also, looking on II's site, I don't even see a "stage 2" turbo on there? Was this put on before you got the truck?

olbattlebuggy 04-02-2012 12:36 PM

Thanks Mdub..
I meant to say Oil Cooler Not the EGR cooler..Ill edit that...
Would you by chance know the P/N for the Turbo oil return line upgrade? I know when i had the Turbo replaced they didn't do it so now is the time.
Speaking of Turbo you are correct. It is a Industrial Injection Stage 1 Hybrid. It was only 200 more for the upgraded wheel size and is suppose to greatly reduce turbo lag. To be honest though I haven't seen any benefits from all my current upgrades in either performance or MPG... I gotta get this FICM re-flashed with a proper tune...Would you see any benefit or recommend any sensor replacement while she is apart.

Mdub707 04-02-2012 01:37 PM

Any idea if your truck is an early or late 04? That will help picking parts out. Late 04 will have the ICP sensor in the passenger side valve cover. Look there, if there is nothing there, the ICP sensor is in the back behind the turbo and it's an early 04. That's the easiest way to tell.

Updated oil drain tube P/N: 6C3Z-9T515-A

Which sinister kit are you looking at?

olbattlebuggy 04-02-2012 02:23 PM

modle year
 
it has a big sensor plugged into valve cover on passenger side closest to front of engine. Ill assume its a later 2004 then correct?

i think i'm going with the MKM sinister package with delete,upgraded OIL cooler, intake gaskets and coolant by-bass filter.

Mdub707 04-02-2012 02:43 PM

Correct, late 04 then.

They didn't really upgrade the oil cooler!? They have upgraded egr coolers it looks like. Personally, I'd buy the Ford oil cooler rebuild kit (tousley sells this for under $250) 3C3Z-6A642-CA and then just a basic EGR delete kit. Whatever gets rid of the egr cooler, and has a new solid up-pipe with it. As for the gaskets, I think I bought a Victor Reinz upper engine gasket/o-ring kit for like $75 on ebay, came with anything and everything (minus headgaskets, which I would ONLY use OEM for). Sinister just buys and then marks up and resells to you. You just pay for the convenience of getting it all in one package. You could save money by purchasing everything separately. I paid $185 shipped for my RCD egr delete kit on ebay, they can be had even cheaper than that now, just as a reference.

bobfbigman 04-02-2012 03:07 PM


Originally Posted by olbattlebuggy (Post 878444)
it has a big sensor plugged into valve cover on passenger side closest to front of engine. Ill assume its a later 2004 then correct?

i think i'm going with the MKM sinister package with delete,upgraded OIL cooler, intake gaskets and coolant by-bass filter.

On the front of the valve cover there is the glowplug module with 2 big connectors on it and behind that would be where the ICP sensor,which is small, goes into the valve cover. it will have a small connector with only a couple of wires in it. Also you can look at the build date on the door post, anything after 9-22-03 is a late build.

dieselbomb87 05-01-2012 11:35 PM

tell that mechanic to 9000 up his ass:moon:

joshbaker 05-01-2012 11:51 PM

hoyl crap man. Im doing STC, stand pipes, dummy plugs, 175/stock nozzle injectors, new icp, and head studs/stock gaskets for just about $5500. Oh and a new FICM with tune from KEM (most expesive but i use their sct tunes and love them so...)

RanchhandTCR 05-02-2012 12:04 AM

9 Grand!!! Chesse and RICE!!!! I can get a new 6.0L Installed for 6K. While M dub here, Got the 6.0L goin good the FICM was good replaced the #8 Inj and its runnin ok for now, but I think the FICM needs a reflash it still get crap for milage.

Crabber0001 07-19-2012 12:17 PM

Engine wiring harness
 
Ford has an updated engine wiring harness for 03-04 6.0L trucks.
I know because I just got one installed by the dealer for free(just bought my truck)(no start).
This curred all my starting problems and everything else.

P>S. Run far away from this dealer he's trying to break you down like a shotgun:


Crabber0001
2002 CC SB L 7.3L
2004 CC SB L 6.0L 4x4

Mdub707 07-19-2012 01:00 PM

Crabber, you don't by chance have the P/N for that wiring harness do you? It's not uncommon for the harness' to become chaffed and not work properly anymore. I believe there is a TSB out pointing out the common wear areas. I know in the FICM guide I have it explains them too.

monster12valve 07-19-2012 05:43 PM


Originally Posted by olbattlebuggy (Post 878415)
Thanks Mdub..
I meant to say Oil Cooler Not the EGR cooler..Ill edit that...
Would you by chance know the P/N for the Turbo oil return line upgrade? I know when i had the Turbo replaced they didn't do it so now is the time.
Speaking of Turbo you are correct. It is a Industrial Injection Stage 1 Hybrid. It was only 200 more for the upgraded wheel size and is suppose to greatly reduce turbo lag. To be honest though I haven't seen any benefits from all my current upgrades in either performance or MPG... I gotta get this FICM re-flashed with a proper tune...Would you see any benefit or recommend any sensor replacement while she is apart.

i also live in cleveland. i live on the eastside and work on the westside. w150th area. if you want to have it looked at local i would recommend mullinax ford, ask for charlie, they will take care of you, they have 2 diesel techs and they both have built 6.0's. if you dont mind the travel, i would check out unlimited diesel. they are down near columbus, but they too are powerstroke gurus. unlimited would be cheaper,


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