2004 F350 6.0l Black Smoke/No Power = Help - Ford Powerstroke Diesel Forum
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Old 07-25-2014, 08:24 AM
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2004 F350 6.0l Black Smoke/No Power = Help

Current Problem:
Hard start, some white smoke initially, smoke increases and turns to black as it warms up, knocking starts to develop during this time, driving around the block reveals no power, engine RPM's increase, speed does not. Feels like a lack of turbo power.

Initial Problem:
Puffs of white smoke, wet EGR valve, oil residue in degas bottle, expected Oil/EGR Cooler failure. Tried to limp home, smoke increased, turned darker and it developed a loud knocking sound. Shut it down, towed it home.

Diagnosing:
Stripped motor down including heads, had broken glow plug tip and intake valve. Installed all 32 intake/exhaust valves, cleaned heads, installed new ford head gaskets w/ ARP head studs, used new injector o-rings and copper washers, stand and dummy pipes, new glow plugs and put the valve covers back on. Next I installed the BPD heavy duty air/oil cooler, BPD EGR cooler, new intake manifold gaskets, new EGR valve gasket and o-rings, new intake manifold bolts, new BPD water pump w/ o-ring, re-installed all cooling system parts and checked for leaks (none). I checked the turbo for obvious problems, compressor wheel looked good, installed new improved turbo drain pipe, IPR screen kit, turbo oil feed tube o-ring and gaskets and installed the turbo. I used titanium exhaust and turbo bolts from BPD and connected the turbo down pipe and exhaust pipes. Installed new glow plug wiring harnesses, and laid the rest of the harnesses into place. I used the new fuel filter o-ring kit and new filters and installed it along with new copper crush washer for the fuel lines. With everything put back together with the exception of the clutch fan assembly I started the truck and had the above problem. I ensured I sealed the turbo down pipe and exahaust pipe again, cleaned out the EBP sensor, checked the MAF sensor and installed the Banks Power air intake kit. Truck started off better, but got worse. Looking for any ideas before spending any more money. Any advice is helpful (No Im not getting rid of the truck).

I still have the Banks technicooler to install, but waiting until it is running right first before I drain the cooling system again.
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