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Old 01-24-2008, 03:21 PM   #1
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Location: COLORADO
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6l PSD Air Noise

***
Posting on this forum to because I am starting to realize many people aren't using or have stopped using the Yahoo List.
***

6l Diesel Owners -

I thought I would put a post out there in case someone else has
experienced this problem. It is a little difficult to explain, so you
might not be able to help.

Recently I towed a trailer from AZ to CO. Near the end of the
600-mile drive I noticed when I accelerated hard there was an air
rushing noise coming from the dog house. I thought oh know, I blew
the turbo! But, no engine codes are showing and the van has FULL power.

After getting settled in I had the time to get it into Ford. I know
what you are thinking. I explained to service that when accelerating
hard (pedal to the floor or uphill pulls) this air rushing noise
kicked in. Let me clarify for this post, this is NOT the variable fan
that kicks in/out. That is normal and I am used to that noise. This
is coming out of the dog house, hence the turbo area. Well, waste of
time! They told me it was noise getting through the dog house seal
because of the SMB installed carpet.

I took it home and removed the dog house. I cleaned the seal area of
any carpet threads and sound-guard tar. I cleaned the dog house seal
well and reinstalled insuring a good proper seal. I knew this wasn't
the issue, but thought why not. My wife and I took it out for a test
drive and same noise. SO, while driving down the road my wife is
upside down with her head in the passenger floor board. The air
rushing noise is actually coming from a big black air handler box down
there. To the right of that box is a flap door that opens & closes
with a small fan behind. Looking at this box it appears to be VERY
difficult to remove. The dog house and passenger dash would need to
be removed to get this box out. I think there might even be a cabin
air filter inside, not sure.

First, I was wondering if anyone else has had this issue or might have
an idea of what it is? Second, I was wondering if this air handler
possibly had a seal that has maybe popped out of place?

Once again, I realize this is difficult to explain and I am only
posting in hopes that someone has had this specific issue pop-up.

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Don
2006EB 4x4SMBw 6l PSD PH Custom - "Zilla"
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Old 01-25-2008, 08:20 AM   #2
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Don -

I saw your post on the Yahoo site too.

Your noise sounds exactly like my experience last summer. The problem for me was a torn high pressure turbo hose. I have a 2005 6.0 PSD. This is a blue flexible hose maybe 2" - 3" in diameter. If I remember correctly, it is located down to the left side of the engine as you look into the engine compartment from the font of the van (under the hood, not behind the dog house).

In my case, I was driving cross country, pulled in for fuel and when I pulled out of the gas station it just let loose. The engine ran fine still, but there was noticeably less power and that rushing air noise under acceleration. I drove it a couple hundred miles this way until finding a dealer in the morning. They found the problem right away, but had to fly a hose in from Denver (I was in Rapid City, SD).

Hope this helps.

Phil
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Old 02-04-2008, 08:36 AM   #3
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6l PSD Air Noise

Is this turbo air hose specific to only the diesels?

Thanks Pat Ohio
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Old 02-04-2008, 10:00 AM   #4
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Quote:
Is this turbo air hose specific to only the diesels?
Yes.
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Old 02-04-2008, 08:30 PM   #5
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Might be this...

Intercooler Hose Blow-Off; Oil Leaks at Intercooler Hoses:
Some trucks may exhibit oil leakage from the hot side intercooler hoses. If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. Hot side intercooler tubes are no longer available as an assembly. Replacement hoses have a revised inner liner that has adhesive properties. Use the following parts as needed to service the condition:
Short upper hose, equal length elbow: 6C3Z-6C640-C; metal tube: single alternator 6C3Z-6K769-B or dual alternator 6C3Z-6K769-A.
Long upper hose, unequal length elbow: 6C3Z-6C640-A; metal tube: single alternator 5C3Z-6K769-AA or dual alternator 5C3Z-6K769-BA.
Use this hose and tube combination if the hose blows off
Clamps: upper hose 6C2Z-6K786-AA; lower hose to tube 6C3Z-6K786-CA; lower hose to intercooler 6C3Z-6K786-EA.
Lower hose, all: 6C3Z-6C640-B.
Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Undamaged hoses may be reused, but they must be cleaned and inspected. If the inside of the hose is blue, it is recommended to apply a thin uniform coating of Motorcraft TA-31 RTV silicone to the mounting surface after cleaning. After reeassembling, allow the silicone to cure for three hours before driving the truck. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off.
TSB 07-5-15.
On 2004/05 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, replace the plastic tube with part #6C3Z-6C640-AA as in recall 05B29 (trucks built from 12-15-03 to 4-1-04), or repair as in TSB # 05-22-3 (trucks built from 4-1-05). Clean the intercooler and intake flange with brake parts cleaner. Seat the hose/pipe onto the intake manifold and torque the clamp to 9 ft/lbs (12 NM). Broadcast Message 1329, TSB 04-20-9, TSB 05-22-3.
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1995 Dodge SMB EB-20 + modified for shower in back, PH Microlite Starcool. 130k miles young!
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Old 02-04-2008, 08:36 PM   #6
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Turbo noise

Mine did the same thing. I think the air conditioning hoses are rubbing up against the turbo hose. In my van they are crammed between the turbo hose...I would not get starcool again. Theirs way to many hoses and parts to the system. Plus you have to have a 3000watt generator to use it.


JM
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Old 02-04-2008, 08:40 PM   #7
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Turbo hose

On mine the hose did not blow off. It had a tear.


JM
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Old 02-04-2008, 09:13 PM   #8
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Mine tore as well. Right at the hose clamp.

Phil
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