[BlindJudge04]

PROBLEM FIXED READ BELOW:

Hello,

I am a long time lingerer on this website and it has been very helpful in the past but after several attempts (lots of parts & labor) to fix my 2004 Ford Excursion 6.0L, we still can't figure out what the problem is. Any advice will be very appreciative, thanks.

Vehicle Specifics:
-2004 Ford Excursion - 6.0L Powerstroke
-123k miles

Parts Replaced, Fixed or Added:
- EGR Delete Kit - Sinister Diesel
- VGT Solenoid - old one broke off inside the turbo.
- Turbo
- New Fuel filter
- Gas Tank Drained to the bottom & new diesel put it.
- Changed oil & new filter
- FICM
- IP Sensor
- Fan Clutch
- Tested Base fuel pressure - fine
- Checked Exhaust back pressure - fine


Symptoms/Problems:
- No Power - Feels like its in limp mode.
- Transmission wont shift correctly - must feather the gas pedal to shift.
- It threw a low boost code today, has never done that before.
- Feels like its not getting good fuel pressure.
- Pedal to the floor will dump out black smoke (lots) doesnt do this until I've been driving for 10-15 minutes.



I have done everything that I've seen to be potential problems but it still has the same symptoms. This has been going on for several months and I've thrown a lot of money & time at it but still nothing, any suggestions would be very appreciative.

 

[[email protected]]

Welcome to the Org!

Does the truck have a EGR throttle plate?

 

[dhanna6powerstroke]

What are you using to diagnose and pull codes? Is it running/idling rough?

 

[LoxDiesel]

Exactly what the BPD Tech said. Pull off the intake elbow and inspect the plate. To close it you should hear an "electric motor" sound and it should spring back open. I usually just remove the plate. Hold it closed, remove the two torx head screws, let it open back up and slide it out. What you're describing points to this.

 

[BlindJudge04]

FIXED THE PROBLEM: Thank you everyone for the info, we solved the mystery problem today. It ended up being the Spark Arrestor (catalytic converter) in the exhaust, the internals were broken into pieces and moving around, thats why it would run alright sometimes.

 

[LoxDiesel]

The catalytic converter.

 

[BlindJudge04]

The catalytic converter.

Yes, but ford calls it a spark arrestor.

 

[LoxDiesel]

Hmm. First ive heard of a cat going out on a 6.0. Does it idle a lot?

 

[[email protected]]

FIXED THE PROBLEM: Thank you everyone for the info, we solved the mystery problem today. It ended up being the Spark Arrestor (catalytic converter) in the exhaust, the internals were broken into pieces and moving around, thats why it would run alright sometimes.

Sweet! Glad you figured it out, sometimes problems like that can be a real pain to diagnose. As stated above, catalytic converter failure is really rare on these trucks.