Turbo again???

[jbenoit28]

When I bought our 05 Excursion (with 87,000miles)it already had the Turbo replaced once. Just a few weeks ago at 119,000miles the turbo stopped boosting and they replaced it again (extended warranty). From reading on this site I asked the tech to replace the VGT solenoid and they said it wasn't part of the warranty repair and that it was functioning fine. Two hour trip to Rainbow river yesterday and half way up there I notice the transmission holding gears a little long. At the next light I open up the throttle a lot more and there is no turbo torque surge like usual. My guess is the vanes are stuck or stopped responding etc. All other temps appear normal (no gauges yet just stock). We arrive and spend the day then get back in the truck to return home. CEL is now on. Truck still drives fine and makes no other indications that something is wrong aside from being sluggish. One other thing, just after this turbo was replaced we went camping. I noticed a fair about of black smoke from the pipe nearly everytime I moved away from a stop. It's never done this before. Coolant went from Max to Min again but no leaks. Any ideas on what could cause this? I have 4000miles left on my warranty and want to get this fixed before I have to pay real money for these issues.

Ordering gauges tonight....

Joe

[colo_dually]

I would advise canceling the gauge plan... Here's why a monitor like an Edge Insight CS/CTS can cover more of that truck for a 1/3 of the cost of a 5 gauge set up. All you'll need is the expandable setup with EGT and Fuel Pressure sensor. I have both in my truck, if you have questions, feel free to PM me.

As for your turbo, I don't understand why the VGT solenoid isn't part of the warranty repair. That doesn't sound right. I would press them to replace/clean the turbo again and replace the solenoid. Reason you saw black smoke with the new turbo, could have been it was still relearning. If it cleared up as you drove I wouldn't worry about it.

You will need to get the code pulled for that CEL and see if its any concern. Fortunately an Edge Insight can do that for you, so you don't get the run around from a dealership/shop.

[jbenoit28]

Colo,

Thanks for the info. I will insist on the VGT this time around.

Sorry, I meant digital gauges. Plan on the SCT setup.

Joe

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[jbenoit28]

My Truck is at the dealer and so far they are stumped...

I hope to get some details tomorrow.

Joe

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[jbenoit28]

No more info. Have a rental till they figure it out. Tech is stumped. Wish they told me what some of the issues were....

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[jbenoit28]

Finally some info:
FORD says:
Turbo inlet clamp is weak
Exhaust manifold had small leak, they retorqued
EGT solenoid was reading very slightly low
MAP sensor not reading properly
And some other assembly needed replacing but I forgot the name.

All told it looks like this could cost a lot. They are calling the warranty to see what they might cover.

Any thoughts? Seems like a little shade tree mechanic replace a bunch of parts at once. Not sure what could cause all this.

Joe

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[jbenoit28]

Oh and the EGR valve was coked up. The MAP sensor was reading low boost at 2psi. I have no idea what all this means.

Joe

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[jbenoit28]

Update:

We got our truck back today. The low boost was fixed by replacing the following:

EBP sensor
Map Sensor
VGT solenoid
Fuel pressure regulator
Turbo inlet clamp
Retorqued exhaust manifolds

All tested marginal and were thought to contribute to the low boost conditions.

Seems like a lot to do but hopefully this also won't need to be done again anytime soon. Took truck on 2hrs trip. All seemed fine now.

Any thoughts on the results? Could something else cause low boost?

Joe

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[jbenoit28]

Can anyone comment on if it's fairly common to have these sensors replaced on our engines?

I just got my CTS. Should have it wired up tonight and will install the EGT Saturday so I can start monitoring things.

Joe

[jbenoit28]

Truck is back at the dealer again! Now I have the CTS Installed so the codes were, low boost pressure, exhaust gas pressure sensor malfunctioning and then a self test not complete.

Any ideas anyone?

Joe

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