Brad Clayton

It's not hard for engineers to come up with those torque specs./techniques with engine on stand, but out in the trenches it's a diferent world.

I was doing a little searching for a sync problem and found these posts, doesn't look good for tech working on truck.

It's a late '04 in which he just installed a short block for a bed plate sealing problem. Truck ran fine before but now the rpm pid is erratic the truck stumbles while driving and the sync pid toggles yes to no.

Anyone had this happen on replacement engines?

Alright, I had a chance to regain my composure after a long day. I was thinking about my original post and I kinda posted without thinking clearly and am setting things straight now.



I replaced the questionable turbo and took some time to tear the old one down, finding this bolt had backed out into the turbine wheel and the entire turbo was not able to turn. I guess a nut and bolt torque check would be advisable on future cleanings.
 

Had one get me good today. 06 with no mgp. Cleaned turbo and egr and installed exhaust manifold gaskets for a p0299 two days ago. Customer comes back and says his turbo stopped working this morning, 23,000 miles on it.

Checked the usual stuff, took control of the turbo and watched the pids, turbo made noise and the ebp_a changed accordingly but no boost. Checked air filter ok, checked map and signal hose which I cleaned previously ok. Swapped map sensor with a downed truck (we got 'em stacked up like cord wood around here) no change. Smoked intake for blown intercooler even though there was no noise or evidence of a leak, ok. Called hotline and told them my mgp started reading (barely) after pressurizing the map sensor to see if it was reading. I had confused the truck so bad it wouldn't hardly move and set a lot of correlation codes, cleared them and I was back to square one, no mgp. I was dead set on a pcm not inferring the numbers had some serious tunnel vision set on, was getting ready to swap pcms. Another tech comes over and says "shouldn't you get something if that turbo is turning?"

I stared engine with air filter off and bingo the compressor wheel wasn't turning. The shaft had snapped, never had one break on me and completely went around a very basic check. I mean come on it's an '06 with 23,000 on it, what's the chances? Oh well, lesson learned.

Excellent repair, definitely one I will keep in the back of my mind on future possible air in the fuel system problems. How much hair did you have left after that job?

Nice, I'll know if they let ya, from the shock wave felt all the way here.

Had one doing same thing, ambulance. A/c worked intermittently also, after tech replaced PCM, with no change replaced harness and cured it. You could actually grab the harness near the PCM and give a good tug when in no start mode and it would start.

Bad part was after getting the harness out (tough job) a week later the egr cooler went out, and it had to be torn down again.

Not sure if this helps but ours hasn't been back been about a year now.

The fluid was done. My wife bought the rig a '97 with 125,000 on it with out my knowledge. I just came home one day and there it was in the yard. So I did not get to check it out before it was ours. Couple of weeks later the noise showed up and I thought it was in the trans and I actually pulled the trans. I found out real quick it wasn't, but it gave me a chance to freshen up the clutches and seals. Like I said my t-case was pretty rough and my wife wanted her "new" rig back so I just swapped it out. The truck has 200,000 on it and it's mine now (wife got a new rig so I got her hand me down) and it still purrs like a kitten. I wouldn't think twice about driving it across country today if I had to.

These t-cases get a lot of abuse, I actually lock into 4x4 anytime conditions allow. It cuts out alot of wear and tear on the clutches.

Noise is in your t-case most likely. I own one and it did same thing. Tore t-case down and found problem with planet assy/sun gear on input shaft moving in and out. Mine was too far gone to fix so I put a unit in it.

I find it amazing how quick the aftermarket jumped on this powertrain. Google "6.4l" and the choices are endless for power adders. I was told by Ford a while back that this vehicle would be unchippable. I guess they were being optomistic.

Holy crap, you took the words right out of my mouth!!

That sums it up completely, and nothing else can put it any straighter.

I like it, and I would fire that post off immediately, to wake the guy up. I personally don't see why he's interested in any warranty problems, him and his buddy obviously have enough money to burn if they purposely destroyed a couple of thousand dollars worth of parts on a brand new truck.

The reason I worded my post the way I did is because the fellow is trying to be sneaky about his mods. He should just man up and put the aftermarket parts on then take his chances with the dealer when something breaks. I for one am very understanding and forgiving on a case by case basis with modded trucks. But if some guy is gonna lie to me and say "hey take a look it's all stock" (when it's not), makes it tough to be in the guy's corner.

There is an old saying "loose lips sink ships", well I think that guys boat is sunk. Anybody with a computer now knows the history on his truck, it would not be hard for him to find himself black listed from warranty repairs.

I can't believe all the tards that are congradulating the guy.

one thing we did when we made a cancel box was to make the harness extra long, this allowed you to pull another 7.3l powered truck beside the broken one and actually run the host truck off the donors electronics, super fast and easy way to tell if it is base engine or electical problem. OF course nowadays it's hard to find two 7.3 liters in the same area, but still worth while to extend the harness. The ford box has a harness that is about 3 inches long, and cost about a grand.

Back in '99, an F-250 came to the shop with a terrible vibration. The truck was brand new and the owner had driven a 1000 miles or so. This thing would rattle change off the dashboard at a stop light. With a quick call to the hotline we find out that 2 engines had been shipped from Navistar with unbalanced crankshafts. We had one and who knows who got the other. A crankshaft was ordered and installed. Truck comes back with an oil leak at the pan. Now I am seeing the truck for the first time. I pull the engine and reseal the pan, the original job did not quite take. Guy is on his way again.

At 11,000 miles truck comes back and has an oil pressure fluctuation problem. I get the truck again and knowing these oil senders aren't the most reliable source I'm thinking a cluster problem. It was a wierd problem because you get run the truck hard and it would be ok, then shut it off and come back to it and the gage would bounce all over the place. To be on the safe side I checked the oil pressure with a master gage and had 20-30 psi cold/fast idle at oil resovoir. Being low I called hotline and they said check it at the fitting down near the oil filter. I did and had 60 psi. Oh boy, 30 up top and 60 down low, where is the oil going?

Hotline says pull the valve covers and looked for a broken lifter causing oil pressure loss, pull trans and check lifter plugs, ect. to no availe. They decide to send help.

Well the calvary shows up. Chuck Gregory and Matt Hahn from Navistar stroll into the shop, we shake hands talk about the truck briefly and they get right to work, I mean all business. I handed them tools and watched. They put the top of the truck back together and then proceed to hook up two oil pressure gages one high and one low at the same time. The thought never crossed my mind. Guess what when the pressure was ok at the bottom it was also ok at the top and visa versa. The pressure loss was in the main oil system. If I had done this I could have saved them a trip to South Carolina. But I'm glad they came down, I learned an extreme amount about Power Strokes while they were there for 5 days. We went to lunch everyday and they bought mine. So we pulled the motor out (this 3rd time now) and hook shop air to oil pressure port with pan off, major hissing from number 4 main cap. We removed the cap and the upper bearing is gone. Tech that put the crank in got side track with a string of waiters and forgot all about that lone bearing laying on his bench!

The bearing was spinning on start up and would block and unblock the oil passage in the engine block, wild stuff. The owner promptly when to the show room and was given a brand new 2000 model. Believe it or not the owner belonged to a travel club in California and made three trips out pulling a 11,000 lb. fifth wheel since the crank replacement.

Anyway these Folks were the best I have had the pleasure of working with. We stayed at the shop til Midnight putting the truck back together with new parts, again they bought me supper. They shared info with me about hush hush stuff at the plant. One topic was the injectors for the 6.0l, another was camless motors they were tinkering with. Keep in mind this was mid 1999. I had some other 7.3's hanging around and they tackled them. They had this wild injector cancel box. I felt like a little kid helping his father fix the car on the weekend, very humbling experience indeed.

I had two guys from International, one being the man himself Mr Chuck Gregory, come down to look at an oil pressure loss. After they found out a main bearing had been left out upon crank replacement, they were pretty upset (more than the customer). These guys take it personally on their level.

See the 7.3l power stroke section for the whole story, I'll post is later.

GUESS YOU'LL JUST HAVE TO SETTLE FOR MAKING MONEY, HUH JIM?

Saw the add for hydrogen retro kits, and have heard alot of buzz about hydrogen and water powered engines (electrolysis) and so on. Any body got any input on this? Are these guys for real with this stuff? I guess anything is possible, I mean we did put a man on the moon, or..... did we?

sounds like a potential buy back.

Once again the proper procedure has broken down on my end. Thanks for the nudge in the right direction, I'll flag a couple of tenths in your name for your leg work.

I guess the old saying "ignorance is bliss" could be applied to these jovial individuals.

Well I bypassed everybody and went straight to the parts guy about this issue. He had already figured out his mistake, (he reversed the numbers and ordered 7 cackles and 1 regular) and got the guy the correct injectors. The fellow reinstalled them on his own (pretty understanding guy in my opinion, lot of work for a parts mistake) and all is well on his end.

This thing has a dump body with an after axle tank, did the water intrusion apply to this year also? I'm too lazy to dig up the article right now, long night.

Customer needed truck and took off before I could go any further with it, so no answers to your question Jim.

No it's all diesel, and the junk inside is that typical, I guess it could be describe as "vaseline" like. We got our share of bio for sure, we even got places to get straight cooking oil. Thank the good Lord, most of our customers steer away from the non conventional fuels. Not too many hippies drivin' super dutys.