60 Diesel
The 2004 Ford F150 6.0 Turbo Diesel has a number of common issues. Some of these can be repaired by the DIY mechanic at home while others will require a visit to the local Ford dealer. The problems discussed in this article apply to all 6.0 International Built Turbo diesels that came in the Ford F series and E series vehicles. These are common in both commercial and recreational applications.
The primary issue with these engines is coking. More specifically both turbo and EGR coke buildup. The increase in emission standards in combination with the low sulfur diesel fuels created a perfect storm of poor efficiency in combustion. The EGR (Exhaust Gas Recirculation) valve often becomes stuck from this coke buildup. The EGR valve failure can lead to a variety of other emissions related malfunctions but the most common is perhaps the EBP (Exhaust Back Pressure) sensor showing a fault. The EGR can be taken out and soaked in carburetor cleaner (as recommended by Ford's own technical service bulletin) and this will sometimes result in proper functioning. Upon cleaning if the valve does not move freely simply replace it.
Another result of engine coke buildup is failure of the turbo charger. This repair can be very costly if the turbo needs replaced. The good news is approximately eight out of ten can be repaired. This repair is not for the DIY mechanic as it requires disassembling a turbocharger by a trained qualified technician. The variable design that provides the always on boost is also the fundamental flaw when it comes to coking issues. The turbo has vanes in it that allow boost to build even before the throttle is depressed and these vanes get gummed up with residue. Additionally the exciter ring often builds up with rust. The local Ford diesel tech I spoke with cleans several per week. A proper cleaning can run in the neighborhood of $500 while replacement is three to four times that amount.
There is no real preventative measure to prevent this coke buildup. The diesel mechanics I spoke with all suggested that driving the vehicle hard regularly will blow most of this buildup out. It seems the highest frequency of repairs is seen in vehicles that are not driven regularly. Ford had a technical service bulletin to this effect at one time as well.
The last and perhaps most common issue with these engines are the fuel injectors. There are two contributing factors to this issue. One is the fore mentioned next generation of fuels. It seems these fuels do not always provide adequate lubrication to the internal components of the injectors. In a diesel the fuel is also a lubricant for these components. The other issue is lack of maintenance. The fuel water separator is supposed to be maintained every fifteen thousand miles. When excess water builds up in the fuel it destroys the injectors. Diesel owners are not always aware of the regular maintenance schedule for these vehicles.
Other issues have been documented with these vehicles but these three are by far the most common. The best advice that one can follow in order to avoid costly repairs is to perform all regularly scheduled maintenance.
