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Discussion Starter #1 (Edited)
We were pulling our 5th wheel travel trailer this past weekend with our '04 F350 and it started smoking really bad (The smoke is pure fuel, not oil) with no check engine light and no engine codes found on my OBD reader at the time. 50 miles down the road we finally did get a light and it said the EGR was bad. We unplugged it and nothing changed so back it went. Since we were out in the middle of the desert we had no choice but to continue on towards home. We finally got to a place where I felt comfortable stopping and continued checking stuff. We noticed a cold cylinder and thought it might be a bad injector so we disconnected it and still nothing changed. It was then that we noticed fuel leaking from around the dead cylinder exhaust manifold. We unhooked the trailer and left it at my brother’s house and limped the truck into Raceway Ford in Riverside, CA. a few miles down the road. The smoke was so bad people were giving me all kinds of grief as I limped along side streets with flashers going.
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It's there now and I'm hoping to hear back later today what it might be. Anybody have experience like this? I'm hoping it's not a cracked block or head problem but it's anyone’s guess right now.

Thoughts?

John
 

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an 2004 6.0.. there is not enough room on this forum to go over all the issues with the early 6.0... super common are the erg cooler and oil cooler. head gaskets like to fail too and so does the fuel injector control module.. and there are all sorts of potential internal engine issues with them also..Man, good luck...
 

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You should go to Ford-Trucks.com and find the 6.0 forum. Lots of info there.
 

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Discussion Starter #4
We've had the truck since new (Oct. '03) and have had a few issues but nothing that serious. A couple of broken turbo clamps, a water pump failure that distroyed the fan, radiator, etc. but nothing like all the others complain about. It's only got 98,000 miles on it!

I have a friend that had all the EGR & cooler stuff ($2,000 repairs) a few years ago on his '08 I believe but ours has been pretty good really. I'm hoping for good news but ya never know.

John
 

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64Pelican is right. Get some knowledgeable guidance. For example, the EGR failure could be true, but probably not, and just a symptom of the real issue. Get it fixed, but don't pay for stuff you don't need. Good luck!

David
 

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Discussion Starter #7 (Edited)
It's a 6.0 ....Worst money pit ever ! Junk it and save $$$
Thanks for nothing. We've had the truck for almost 10 years and closing in on 100,000 miles with only a couple of problems until this and none of the issues that everyone talks about. It looks like new and was maintained very well. While not Fords pride and joy they're also not as bad as many say. The internet tends to blow things out of proportion and it was only a small percentage that had major issues. If you saw the truck you probably wouldn't say that but whatever.

64Pelican is right. Get some knowledgeable guidance. For example, the EGR failure could be true, but probably not, and just a symptom of the real issue. Get it fixed, but don't pay for stuff you don't need. Good luck!

David
I'm working on that right now. It's being towed home as I type and I've got a friend that is a diesel tech and he's going to look it over for me. We're going to try replacing the bad injectors, oil, etc. and see what happens. Maybe I'll get lucky!

John
 

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65 NO the internet dont! I work for FORD ! Worst MOTOR EVER ! I do more work on 6.0 with less than 100,000 than any other with over 200,000 ... We wont even take 6.0 on trade ! hows that for ya ....
 

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Worst MOTOR EVER !
Yeah, but I love their turbochargers! I have a couple matched pair waiting for projects. You can get them for beans, spend $50 to clean them out and re-seal, and have a turbo you couldn't afford for next to nothing. Gotta love standard replacement items!
:D
David
 

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Exactly - and yet there is usually nothing actually wrong with them, as a victim of other issues like stuck injectors. They are the bread and butter of turbo rebuilders as they only need a clean-up to be 100% operational, and sold as 'rebuilt' or 'freshened' instead of fully remanufactured. Easy money as most folks don't have over a grand for a new or reman one with every 6.0L hiccup. If they didn't need electronic control to use the awesome VNT feature, folks would be standing in line for them for their hobby cars. I have that covered. ;)

David
 

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I heard the injectors on those are lubed by the fuel. Buddy of mine had a mint low miles 6.0 and it gelled up on him and cracked an injector or two. I realize gelling is not an issue in the dessert but fuel pressure regs can kill the injectors also. Once the injector goes bad then she will smoke like that as well from what I've heard. Good luck with it! Once you get it fixed if it's not too spendy of a repair I would consider a trade for one of the new 6.7's. Same guy I mentioned above just bought a brand new one and just loves it. Gets 21 mpg and said it pulls like a dream. I personally am staying away from the newer diesels. Found a '96 1 ton dually with low miles and a 7.3 turbo. The 7.3's were IH built and bulletproof well past 300,000 miles.
 

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Discussion Starter #16
The motor is totally stock with the exception of the replacement K&N filter which is coming out before it goes back on the road. I have good conections at Ford (an experianced diesel tech and an Aftermarket Zone Manager) and both have suggested stuck open injectors and both thought it's a good bet it's salvagable. The dealer who first looked at it said #5 & #7 but my buddy will verify before we go too far.

Right now we're thinking two new injectors, oil & fuel filter changes and give it a shot. It did have fuel leaking out pretty bad when we first were able to take a good look at it. It appeared to be coming from around the exhaust manifold. I looked under the truck when it was being dropped off on the flatbed and there was a trail of diesel fuel from front to back on the passenger side so I know it must have been spraying out pretty good. Because of that I'm hopeful it wasn't locking up the cylinder but I'm not sure of my logic there. Blowing out the exhaust vs. hydro-locking the cylinder? I don't know.

Anyway, my mechanic buddy is supposed to stop by tonight to give it a once over so I hope to know more then. Thanks to all for your feedback so far.

John
 
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