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6.0 Ford coking problem in the intake causing EGR problem

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7.4K views 6 replies 3 participants last post by  sinner6.0L  
#1 ·
Good morning everyone. The other day I was driving my 06 F250 6.0 down the highway and all of a sudden it lost all power and starting blowing thick black smoke. Having knowledge of the problems with these engines I thought right away the EGR valve was clogged up.The truck would not even move in drive. I had it towed to the dealer and they told me that the intake was coking up from the bad diesel in the US. I put a diesel treatment in the tank everytime I fill up. They said that the truck had to be set up and a series of chemicals injected into the motor for 4-1/2 hours to clean out the intake and EGR. Has anyone had this done before and if so how long did it last before it happened again. Also will an EGR delete kit resolve this problem? If so would I still need to get the intake and EGR cleaned out first? The truck has 69,350 miles on it. Last August they replaced the EGR cooler, egr and oil cooler. Thanks in advance!
 
#2 ·
This would be a unique case if there is actually enough gunk in the intake to cause the motor to limp like that all of a sudden. What was your boost level when you lost power, and did you maintain any boost afterward. You could have an issue with the turbo, or a boost leak somewhere, and it would be more along the lines of an 'all of the sudden it lost power' situation.

As far as that treatment, there is no way I'd have them run that through my motor. I don't know the chemicals used, but its something my dealership wanted to do on mine, and I said no. There is no reason to have that blown through your cylinders, and turbo. The reason they do it this way, is there is less labor involved in it, because you're not tearing apart the motor.

What I would do is have them remove and clean the intake and egr valve and cooler. That's the right way to do it, take the parts out, clean them properly, ensure they are clean, and re-assemble. Ensures that was the issue in the first place, and ensures everything is actually cleaned up completely. Since its already at the dealership, you are kinda tied here without towing the truck again.
 
#3 ·
I wasn't thrilled at that idea either. They told me that they could clean the EGR valve and that if it breaks down again because another chunk of carbon gets stuck in the valve not to call them screaming. They have since cleaned the valve and it runs and drives ok. I still have it there.
 
#4 ·
Right there is the reason dealerships have a bad reputation. Trying to force an owner to take that route, and guilt them into it.

If the truck drives now, I'd get it out of that dealership and find one that is a little more experienced with the 6.0L to look it over.
 
#6 ·
They wanted to do it around the same time as the HG's, preventative they claimed. I made it clear on the work order it was not to occur.

Are for EGR delete kits, I'm not a supporter of. Mainly its federally required emissions equipment and I'm not going to risk the fines associated with a deletion. If you intend to take the delete route, I'd recommend the block unit from BPD, same function but it looks 100% stock. As long as you do not have the latest flash from Ford a CEL won't be an issue.

I'm going with the BPD upgraded EGR cooler the next time my oil cooler requires a rebuild.
 
#7 ·
You're not going to clean out the intake manifold with some magic chemical. You need to remove the intake and either pressure wash it or have a rad shop hot tank it.