Weird whistle/squeal on 03 6.0L - Ford Powerstroke Diesel Forum
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post #1 of 10 Old 01-07-2020, 07:40 AM Thread Starter
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Weird whistle/squeal on 03 6.0L

Hey guys, I have a weird noise with my 03 Powerstroke CCSB 4x4 ZF6. Just bought it the other day, got a really really good deal on it so don't mind if I have to fix things.

When I'm at about 1k-1900k or so rpm, and maybe some other times that I miss, I get this weird whining/squealing/whistling noise. It kind of sounds like something between wind noise and a whiny blower motor. You know, like when you get an older car and it is cold and the blower motor squeals for a bit before it warms up? Weird analogy, but I drive old stuff so I'm used to it. Haha.

Anyone have any ideas? I don't have a scanner, but my boost numbers seems to be ok and my EGTs are not out of the ordinary. No real smoke to speak of unless I am mashing on it, so pretty normal.

Tried to get a good video but can't hear it very well. I'll see if I can get a new one.

This is my first Powerstroke (and only my second Ford) and my first diesel with the variable vane turbo so I'm not sure if this is normal or not.
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post #2 of 10 Old 01-07-2020, 03:50 PM
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Possible belt slip squeal. Mine has done it for years and I keep saying I am going to shim up the alternator to see if that cures it but never seem to get the job done. Good luck
BTL
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2003 Lariat 4x4 CCSB 6.0
281,500mi
KC Stage 2 Turbo, KDD heads,
ARP Head studs,
175-30 injectors, Adrenalin HPOP
MBRP 4 SS Turbo back
BPD HD remote air to oil cooler
BPD water pump and EGR Cooler
Hayden mechanical fan clutch
Amsoil 2 micron bypass filter
Mishimoto Radiator, HT thermostat and hoses
Mean Green 220amp alternator
Odyssey 65-PC1750T batteries
Accurate Diesel adj. FP regulator cover
Fass Titanium 125 with 5/8 draw tube
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post #3 of 10 Old 01-07-2020, 05:01 PM
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Does the sound change with the turbo?
Could be a turbo boot leaking or split or the tank gasket on the charge air cooler
or, one of the up pipes bellows cracked

--if the sound changes with RPM only, then maybe the serpentine belt
or a idler pulley

Sitting still and revving the engine, can you cause the noise?
Brake torqueing, can you cause the sound?

Possible if you only hear it when driving, it is a wind noise?
window vent shades or a bug guard

In my defense, I was unsupervised
.
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post #4 of 10 Old 01-08-2020, 07:22 AM Thread Starter
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It is definitely in synch with the turbo. Only when on boost, when backed off and letting the engine brake I don't hear it.

I'm thinking it might be a turbo boot or something, too. I'm going to check tonight.
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post #5 of 10 Old 01-08-2020, 08:45 AM
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Pull the turbo intake pipe and inspect the compressor wheel
should be no end slack, but a little side to side is ok
long as it does not touch the housing

There are several vids showing a DIY pressure tester
a Fernco coupling and a 4 inch cleanout plug works well
you just want the threaded plug to clamp in the Fernco
apply up to 30 psi on the turbo inlet -- also can use on the exhaust pipe to check for leaks

In my defense, I was unsupervised
.
2006 F250 Lariat FX4 cclb
Torque Pro and OBDLink MX bluetooth monitor
General note:
For all those wanting a premium silicone sealer Kubota 70000-73764 is the best your gonna find. This is a hybrid gray silicone that uses solvent rather than acid to start the curing reaction, this makes it safe for aluminum and and any surface that involves coolant.
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post #6 of 10 Old 01-09-2020, 07:30 AM Thread Starter
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Well, went out and played with the truck some. All the fittings are tight and doesn't appear as if there are any leaks. It is definitely coming from the turbo though. The impeller wheel is not loose, no real play and I'm not seeing any contact on the inlet side. I'm kind of thinking it might be the bearings, it sounds like it is coming from the compressor housing area on the pressure side.
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post #7 of 10 Old 01-09-2020, 08:39 AM
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The vanes on the exhaust side can wear and come into contact with the turbine wheel, damaging the fins on the wheel
only way to check is to pull the turbo and split it open
depending on the miles on the turbo, it may be good to check anyways
at that point, you can decide to rebuild or replace

For sure the up pipes are good?

In my defense, I was unsupervised
.
2006 F250 Lariat FX4 cclb
Torque Pro and OBDLink MX bluetooth monitor
General note:
For all those wanting a premium silicone sealer Kubota 70000-73764 is the best your gonna find. This is a hybrid gray silicone that uses solvent rather than acid to start the curing reaction, this makes it safe for aluminum and and any surface that involves coolant.
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post #8 of 10 Old 01-09-2020, 09:24 AM Thread Starter
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Quote:
Originally Posted by Hydro View Post
The vanes on the exhaust side can wear and come into contact with the turbine wheel, damaging the fins on the wheel
only way to check is to pull the turbo and split it open
depending on the miles on the turbo, it may be good to check anyways
at that point, you can decide to rebuild or replace

For sure the up pipes are good?
Yeah, all the up pipes are good. The truck has 290k miles on it. Probably worth it to replace it.
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post #9 of 10 Old 01-10-2020, 09:43 AM Thread Starter
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Welllll, looks like maybe it is the up pipes after all. I had a friend at work come and listen to it and we were able to rev the engine while the other listened under the hood and fairly certain it actually is coming from the up pipe area.

The truck is not deleted/upgraded so looks like it is time to do some work with the EGR cooler. Probably going to delete it, no smog stuff here for diesels.
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post #10 of 10 Old 01-13-2020, 05:39 AM Thread Starter
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Fixed the problem! I was screwing around with the truck on Saturday and tightening all the clamps and found the clamp to the EGR cooler was not tight. Torqued it down and no more noise and the truck runs so much better. Quieter but more wheeeee out of the turbo.
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