Solution to an old problem

[Mr.Steve]

This is my first post, although I"ve been a lurker here for a while. I've seen several posts on this problem and thought my experience/solution might help others. My '03, 6.0L Excursion had a fairly common problem of bucking, sputtering, misfire on light to middlin acceleration and some major turbo flutter at times. Drove me nuts 'cause it was intermittant. Finally succumbed to sending to my regular shop which claimed the turbo was at fault and so I paid through the nose for a stock reman from Ford. One unresolved clue was it was throwing a MAF code but a new module did nothing so they put the old one back on. Took it on vacation and it still didn't run right...no power now, shift points WAY too high, poor economy and even worse turbo flutter. Fed up, I called 2R's and Ray diagnosed over the phone. The connector to the MAF had a broken wire. Pulled on each one individually and sure enough one stretched, indicating it was broken. Ran it over to 2R's and had the wire repaired and she ran like before there was ever a problem! After that, had it flash tuned for another 75-100 horsepower and she runs incredible. The tune also turned off the EGR, so the cooler will now never get hot and may never leak. Response and power are way up over stock and economy is better as well. I'm a happy camper (with a new diesel mechanic)

[dannyboy950]

Nice find could also apply to any of the sensors used to determin fuel strategy.

[PGreenSVT]

Originally Posted by Mr.Steve

This is my first post, although I"ve been a lurker here for a while. I've seen several posts on this problem and thought my experience/solution might help others. My '03, 6.0L Excursion had a fairly common problem of bucking, sputtering, misfire on light to middlin acceleration and some major turbo flutter at times. Drove me nuts 'cause it was intermittant. Finally succumbed to sending to my regular shop which claimed the turbo was at fault and so I paid through the nose for a stock reman from Ford. One unresolved clue was it was throwing a MAF code but a new module did nothing so they put the old one back on. Took it on vacation and it still didn't run right...no power now, shift points WAY too high, poor economy and even worse turbo flutter. Fed up, I called 2R's and Ray diagnosed over the phone. The connector to the MAF had a broken wire. Pulled on each one individually and sure enough one stretched, indicating it was broken. Ran it over to 2R's and had the wire repaired and she ran like before there was ever a problem! After that, had it flash tuned for another 75-100 horsepower and she runs incredible. The tune also turned off the EGR, so the cooler will now never get hot and may never leak. Response and power are way up over stock and economy is better as well. I'm a happy camper (with a new diesel mechanic)

I wouldn't count on that at all my friend. Under high boost conditions the gasses can still sometimes unseat the egr valve and push past. Unless you remove the egr cooler or weld plugs in the ends to make sure nothing comes through you just don't really know. Turning the egr off in the tune will help get a better response but it is far, far from a guarantee that you won't suffer a ruptured egr cooler.

[Mr.Steve]

Agreed. I'll never be totally safe until its deleted.