New Engine?
 

Truck:
2008 6.4L Ford F450 XLT 4x4 (Crew Cab & Flatbed) 157k mi

I am new to the diesel powerstroke family but have been driving a Jetta TDI for ten years so I am not totally ignorant when it comes to diesels but this truck has me stumped - now seeking all possible advice.
About two months ago I started to notice what seemed to be excessive black smoke coming from the tailpipe during acceleration but a fellow powerstroke owner said it was standard procedure. The issue persisted until last week when the black smoke turned white and was billowing out of the tailpipe - heavy during acceleration but persistent while running. After ten minutes or so of the white stuff we got the "pullover safely now" warning and the truck died following with a no crank no start. We were able to get it started back up by disconnecting/reconnecting the batteries. Aside from that, there were no other discernible issues. No weird noises, no loss of power, etc. We got it into the Ford dealer that day and it took 5 days to get the diagnosis "You need a new engine". This post is getting long so I will cut to the mechanics synopsis - word for word
"Found engine to have excessive crankcase pressure even at idle it will blow the oil cap lid off. Found oil entering the inlet of the turbo through the pcv system. The oil is entering due to the crankcase pressure. Ran relative compression and 2,6,8 were down 4%, completed manual compression and all lower than normal (lowest 180 highest 205). Contacted hotline - says engine failure, also to replace doc, and DPF due to contamination. Also pulled the oil line to turbo and it is sludged up. There is no oil on the oil stick. Engine more than likely scuffed the pistons and bearing due to low oil. Pulled codes that are listed, in freeze frame egt12 was at 1600 degrees while egt11 was at 500 and egt13 was at 700."
To me, it looks like they did a fine job with the inspection but I wanted a second opinion on the diagnosis that I need a new engine. What is standard for compression psi in the 6.4? They want $22k to do all of the necessary repairs - needless to say, I drug it back home and will find another repair shop if necessary. Any and all help would be greatly appreciated. Thanks!

Sounds like a reasonable diagnosis. no oil on the stick is a pretty good sign of lots of blowby and like the mech stated probably scuffed pistons coked up oil control rings and the heat from the 1600 degree temp is going to do its damage on the exhaust valves, the manifold,and turbo exc.
Where are you located maybe someone on this site can point you to a good shop or be of some assistance?

Thanks Jet A Fuel. I did a bit more research after posting last might and came to the same conclusion. I have talked with the dealership I purchased the truck through and they will be getting me a Ford replacement at cost. I live in Clear Lake, IA but am probably going to haul the truck up to Midwest Transmission Center in Hader, MN. Talked to several 6.4 owners and the place sounds legit. Gonna get the new one bulletproofed.

It would be worth while to get a set of gauges or a programmer to put on the truck so you can monitor engine parameters especially if your towing a lot. Just the basics fuel, boost and exhaust temp. I don't know of any shops up that way but I used to work in Iowa City and Waterloo and its gonna get cold as well diggers :moon: in a couple months!!

hello all I have a issue I removed the egr and put a delete kit on and now I have no power at all doesn't like to shift and have seven codes p0405, p1335, p0488, p2610, p0652, p1260, p042e, p1000 I think I need to drive it more to get the diagnostic to run on the computer but not sure why the p2610 ecm/pcm internal engine off timer performance is any help would be appreciated thank

Did you buy a race tuner ??

hey gunman I got a tuner and the dpf and cat delete pipe and shit what a world of diffence damn truck is a beast now got a 70 hp tuner love this truck now thanks for the help

No such thing for the 6.4, that engine is designed to fail, worse than the 6.0. Look into powerstroke help on you tube.