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Problems with 2004 6.0 liter powerstroke, fresh gaskets and studs, no power
I need some help. While in Afghanistan, I had Lead Foot Diesel Performance pick my truck up to fix leaky head gaskets. Let it be known that they went out of their way to go get my truck while I was deployed and then had the truck done before I got home. Very commendable. Vinny dealt with me mostly through email, which is inherently difficult.
They replaced the head gaskets with oem head gaskets, used ARP hardware and headstuds, o-ringed the heads, rebuilt the FICM, replaced 3 injectors, replaced the HPOP, and added a regulated return fuel system. They also installed an SCT Livewire TS 5015. That's where I am having the problem.
First of all, when I was on the way home, I noticed that the "Turbo Boost" wasn't changing. It just read -.40. Every once in a while it would change to -.44, but otherwise it just stayed statically at -.4x. I could hear the turbo spooling up, but the SCT gauge didn't indicate anything. I changed it to manifold pressure, and I don't remember what it read, but it also wasn't changing. I called SCT and they wanted me to call them back when I got home and could hook a laptop up to it.
The SCT Livewire comes with two tunes. Performance and Street. When I put in the performance tune, the truck feels 20-30 hp stronger than stock. When I put in the street tune, it feels like a dog (much weaker than stock). I figured these were canned tunes, and didn't put much thought into them. I called Innovative Diesel and ordered three tunes from them. They recommended a 120hp tune for towing, a 150hp tune for daily use, and a 190hp race tune. The 190hp tune feels like a gain of about 40 hp. The 150hp and the 120hp tunes, feel real sluggish (again weaker than stock). When I say they are sluggish, I mean, the truck doesn't feel like it can get to the end of the gear. The transmission won't shift until ~4k rpms because the computer is registering a WOT condition, but the truck takes for ever to get to 4k rpm.
Each company is defending their product and I don't doubt any of them. SCT had me overnight my tuner back to them, so they could test it, and it checked out perfect. Innovative says they have sold those tunes to countless people and that 190hp tune should be giving me mahogany. Furthermore they claim their 150 and even the 120 should be making my hair stand up. I don't doubt them either. Lead Foot, says they built the truck right, and they build 300+ 6.0Ls every year, and if there had been a problem they would have identified it. I have no doubt about that because the truck purrs. Unfortunately I don't need the products defended to me. I believe in them. But I need to figure out what is wrong with the truck.
I don't believe in coincidence. I think the boost not registering (despite me hearing the turbo spool up), and the tunes not yielding much performance are definitely related. Has anyone heard of this problem before? Anyone have any suggestions? There are no dyno shops near me I don't think (I live in Evans, GA). I am going to try to find the MAP sensor and look at it with a multimeter (this was a suggestion by Jesse at SCT). Can anyone think of anything else? I am hoping someone jumps in and says, "Oh yeah I had that. It's a..."