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Dealer replaced EGR & Oil Cooler...Issues ALREADY within 2 WKS!
2006 KR F250 stock other than SCT with Looney file and straight exhaust
My problems. 3 weeks ago I brought my truck to the local Ford dealer for a long start and rough idle condition with accompanying white smoke. They ran diagnostics with the following findings. Low FICM Voltage at all stages, bad EGR Valve, bad IPR, EGR and Oil Cooler failure, damaged STC fitting, and damaged o-rings on the dummy plugs.
All were replaced along with the updated FPR kit. The dealer had my truck for almost 1 week.
I received the call that it was ready for me to pick it up. While driving home I noticed that it was smoking at each red light and once I was rolling again it went away. I called the shop and was told that it was normal after that type of repair and that it would stop after a couple of days or a good drive in it. Well fast forward 2 weeks and 1200 miles later, the smoking is still present. It is a light white smoke at idle after start up and subsides after about 30 seconds. The 1200 miles is in part of a trip that I took to central Oklahoma while I was on leave. Once I arrived in Oklahoma (and several times throughout the trip) I checked for leaks and fluid levels - all was well. The next morning I walked out to find a puddle of coolant under the truck and noticed it was leaking from a loose hose clamp. Tightened it back up and the leaking stopped.
Now fast forward to this morning (1 week later and have now returned home to Mississippi), I walked out to the truck and hit the key...about 15 seconds worth of cranking she fires up with a huge cloud of white smoke engulfing my truck. I instantly turned it off! I popped the hood to find that I have lost more coolant with no leaks present at all. The level is approximately 3/8" below the min line. I pulled the new EGR Valve and found dropplets of coolant and a damp intake. No puddles inside just damp. After that I jumped back in and it fired right up within 2 seconds. I know that the dealer has a 12 mth/12000 mile warranty on this and no doubt I will be bringing it back to them first thing Monday morning.
I was wondering if anyone else has had an EGR cooler fail this soon after replacement? I never dogged or beat on the truck. Nor did I tow anything. I am hoping that I did not damage the head gaskets (and if so, would the dealer be liable since they checked them and they were good and this is in part to the EGR cooler failure?) or have an injector failing.
Sorry for the long read, I just wanted to be as informative as possible. Any input would be great.
SCT X3 running Looney by Vivian!
High idle mod