Archived HELP!!! 2007 Ford F650 w/ Cummins ISB 5.9 (non DEF) black smoke under acceleration

[BuckeyeTowing]

We have a 2007 Ford F650 rollback with an ISB 5.9 mated to an Allison 2200 RDS. Under acceleration low and heavy, the truck produces large amounts of black smoke. I get an intermittent service engine light but no codes show in the ECM. I just need someone with some good diesel logic that isn't just chasing a computer program and running up a bill. We're about 18,000 deep at this point and still smokes and low power. Im hearing that the spin-on fuel filter housing may be cracked internally or that the fuel return hose may have a clog, other than that..... Nothing. The attempts (under advice of the Dealer, Cummins Bridgeway, and diesel shops alike) to fix this issue include:

Complete in frame engine rebuild,
cylinder head checked, valve job
injectors removed and tested, 2 replaced,
new turbocharger,
EGR valve cleaned, inspected, and functioning 100%,
new exhaust,
charge air cooler pressure tested,
software updated,
new transmission,
fuel tank removed and cleaned,
throttle pedal sensor replaced,
air cleaner replaced

 

[NIsaacs]

The charge air cooler was pressure tested for leaks but maybe it is plugged. Maybe some mechanic somewhere along the line left a shop rag in it. How about an exhaust brake, does it have one and what type.

Nick

 

[p-Bar]

Get boost gauge on it and see what is happening. As nick says exhaust brake?

 

[Wayne M.]

5.9? EGR valve?
The intermittent light bothers me. This happens, and there are no stored codes? I'm thinking an electrical gremlin after making sure there are no mechanical issues, like a clogged I/C. NIssacs suggestion. Boost gauge is tricky because if something (electrical gremlin) is holding back the fuel advance, there will be low boost. Is anyone using legit Cummins software or (I guess Ford IDS) since the light started?

 

[cerberusiam]

Boost, LP, EGT, and rail pressure gauges to see what is happening or you are just guessing.

Might change out the MAP sensor as a quick, cheap test for a problem.

Are you sure it isn't a 6.7? Year and build suggest a 6.7 but anything is possible.

 

[BigPapa]

What color is the motor?

 

[BuckeyeTowing]

Thanks for all of the replies, sorry for the slow response from me. (NIssacs) Pulled the charge air cooler today, nothing inside but did notice a few of the passages inside were smashed/closed off. Carefully straightened them with a flathead. Still smokes. Also removed the fuel return and checked for restriction and found nothing. (P-bar, cerberusiam) Boost guage reads 25lbs at wot from a stop, 30 at wot up a grade. no egt or fuel pressure guage at this point. (cerberusiam) It is a 2006.5 build, 2007 model year. Would it be possible that the previous replaced sensors with those from a dodge not understanding that the engines are different causing the values to be present but incorrect? Just a hunch. Oh, and the exhaust brake question. It does have one. There is no elbow or butterfly. The Turbo is a Holset HE351W The exhaust brake appears to work internally within the turbo. It works GREAT when switched on, possible that it isn't opening completely when its off??

 

[cerberusiam]

HE351W does not have an integrated EB, that would be an HE351VE which is another subject entirely. Those can have problems and cause your symptoms if the collar that controls it sticks. A turbo cleaning on those is a normal needed event in a lot of cases.

Any Cummins engine in front of an Ally is going to be managed and derated in power, they are generally only 200-220 HP and never get to build TQ very high. In a heavy truck they really feel doggy.

The black smoke means there is too much fuel and not enough air at the correct time. Could be the turbo, could be sensors, could be injectors. A Cummins shop should be able to work on these and diagnose them.

A simple thing to change would be the MAP sensor. If it really has EGR and a VE turbo they can suffer from the exhaust being routed back thru the intake and get dirty.

 

[mwilson]

Can you provide the ESN so we know what exactly we are dealing with??

Also, are you sure that the transmission is starting out in 1st gear???

Mike.