04 f350 Barking noise, Bad Turbo?

[tony2fingers]

When i got my truck last year, (04 f-350 dually 6.0 90k miles)I drove it home and it made a barking noise (turbo farting) when i was going up a hill or applying power whenever i drive it and its hot outside. The problem is exactly like the video im linking below. Except that now its allways making the noise, not just intermittently.
YouTube - Ford Turbo Problem

Fast forward a year, its been an intermittent problem so i never adressed it untill this week. I let my buddy borrow the truck to tow a trailer (20 foot 9k lbs) and the tentioner idler broke. He changed the idler and belt and drove it for an hour through sacramento this week, temp was 113-120 degrees, it was making that noise before and after the belt blew. While driving, the engine shut off. found out it was the #22 main motor fuse computer, replaced the fuse but now when he drives the truck, it make the noise anytime the throttle is released, or the engine is reved over 2k, not just going up a hill when its hot outside.

I did some research and told him over the phone to pull the EGR valve and see if it makes a difference. He mistakenly pulled the Control Valve for the turbo, but the barking stopped. drove it home and now i have to fix the motor. The truck still drives without the turbo control valve plugged in but its seems like its a normally aspirated diesel, no power at all. I plug in the controll valve and still no power, but lots of the barking noise though. i lightly cleaned the egr valve, and the Control Valve, but the problem still presist, no diference.

Im assuming the its the Vanes in the turbo sticking, or the EBP Sensor, EGR valve, Or Controll Valve for the turbo.I just cant figure out if it was intermittentbefore, and after a day in 120 degree towing, what would fail and make the intermitent problem become a constant. I just hate for it to be the turbo and need replacement. Please any advice would help, and if it is the turbo, any advice as to replace or repair would also help. I'm probably going to remove the turbo this weekend and try a rebuild/clean process Thanks for all your help in advance.

[sweetdeeillusion]

Ford did a software update that had the VGT vane move more than it used to. On some older trucks the vanes would stick and cause the barking noise you described. On others it caused the vanes to stick. New turbo is the fix.
All 6.0 will bark under high load on/off throttle loads. Nothing to worry about, normally.

[tony2fingers]

The problem is that when the truck makes the barking noise, i get MAJOR loos in power, as well as the engine jerks. I think if your towing a tailer and you have now power to pull up a grade, and the engine is making very starge noises, it would make you worry a bit, or even panic.

[dmalmgre]

Originally Posted by sweetdeeillusion

Ford did a software update that had the VGT vane move more than it used to. On some older trucks the vanes would stick and cause the barking noise you described. On others it caused the vanes to stick. New turbo is the fix.
All 6.0 will bark under high load on/off throttle loads. Nothing to worry about, normally.

He's talking about when he is on the throttle it's making the noise. It is not normal for the motor to do that. My dad has an 04 f250 PSD 6.0 and it's doing the same thing. Usually going up a hill with about half throttle it'll do it or when you're getting on the interstate or somethin. I'll keep you updated on our progress.

[bas157]

Mine was making the noise, only when getting off the accelator pedal. Took it to the dealer, they gave me a print out of a bulletin from Ford saying the noise was normal. Funny thing is, it has never made that noise since I got it back from the dealer! (knock on wood).
They told me it is acceptable and printed out bulletin for me, It is #18845 and reads
"Flutter noise on deceleration
Some vehicles equipped with a 6.0l diesel engine may exhibit a flutter type noise from the air box/intake area on deceleration. This noise typically occurs when decelerating after heavy acceleration. The noise is a normal characteristic of this engine and has no impact on engine or turbocharger durability. No repair should be made for this condition. Effective date: 09/21/2005"
Had 21k miles on it at that time.

[sweetdeeillusion]

Turbo flutter was what Ford called it. The reflash was supposed to minimise it. But it never as far as I am aware cause a power loss. Sound like theres more going on than simple turbo flutter. Power loss could still be caused by the turbo. The VGT controls boost, try disconnecting the VGT actuator and drive the truck and you will see the difference. If I come up with any ideas I will post.

[dmalmgre]

Well here's an update. Ford called yesterday and said that the turbo was bad but their tech had already R&R'd the old turbo without our authorization and the bill was going to come out to $3,000. The idiots called to get authorization after the repair was done. My dad went in and talked to whoever it is at Mike Naughton Ford in Colorado who is above the service manager and told him what was going on and the knocked a bunch of labor off, then knocked another 10% off and threw in some free ****. He walked out the door paying $2,000 instead of $3,000 for the whole turbo replacement. Not sure how much the VGT turbos cost new but it still sounds a tad high to me, but he's happy. Chances are you're going to need a new turbo there OP.