Worried about reliability

[iam14]

I have a 2007 F550 with the 6.0 liter engine (approx 82,000 miles on it). I use it to pull a 18,000 lb GVWR 5th wheel toy hauler RV. Two weeks ago while traveling from New York state to Colorado, the exhaust tube on the turbo popped off at the turbo end. I had a diesel mechanic re-attach the hose, we went another 20 or so miles, it popped off again. I reattached and it lasted another 50 miles and came off a third time. This time a diesel mechanic shop replaced the hose and both clamps. That lasted about another 50 miles and it popped off at the other end (same hose).
We took the truck to a Ford dealer in Pennsylvania and he said that the turbo fins were corroded and weren't able to adjust the pitch properly. He had the fins cleaned and ground down to work properly.
That seemed to solve the problem for the remainder of the trip, but since we rely on the truck 99% of the time and we live in the 5th wheel rv, I'm concerned about the reliability of the 6.0 L engine. Everybody I've talked to says that the 6.0 L was "not Ford's best engine" (and I think they are being polite).
After all that long-winded explanation, here's the question. Can the engine be replaced with a, possibly Cummins, engine? About how much would that cost (I won't hold you to any dollar figure, I just want a ballpark). Also, if it's more economical, can the 6.0 L engine be rebuilt or refurbished to provide greater reliability?

Please, no flames against the Ford. I know it's easy to do, but I didn't know any better when I bought the truck and I'm on a limited budget or else I'd head out and trade it in on something else. Thanks!

 

[Deleted member 995608]

A Cummins conversion is going to cost you an extreme amount of money. Id guess at least $15/20k for a reliable swap that includes a low milage or rebuilt engine and transmission of your choice.

You'll need to spend some time of the Powerstroke forum to further investigate your questions.

 

[JR]

Not sure how many miles on your 6.0 But if its been trouble free up to this point your doing better than most. There is a HUGE class action lawsuit out against the 6.0. Google "Destroked" they are a company dedicated to Cummins conversions in Fords. I imagine it would be quite pricey depending on the route you choose. Most people buy a donor truck, such as a wrecked Dodge with a good drive train, and have most of the needed parts to do the swap. Dropping in a brand new turn key engine would drive the price up considerably.
FYI, a new 3500 Ram dually will pull that 18,000 5er and be well within its limits. They recently tested a 13 Ram 3500 against a 13 F450 and the Ram beat the 450 in nearly every aspect.

 

[PDM]

Hi, sorry to hear that you have had problems with your truck. I honestly don't know anything about the turbo boost problem you describe, but possibly a search on the Ford forum will yield some information:
http://www.thedieselstop.com/forums/
I would be inclined to wait and see if your turbo service has fixed your problem, perhaps a test loop planned around a location with readily available service? I was under the impression that the later years of the Ford 6.0 engine were more reliable, so hopefully you are good for many more miles! See what they say over at the Ford forum.

Have a look at these places specializing in Cummins conversions to Ford trucks:
http://www.destroked.com/
http://dieselconversion.com/
If you do the work yourself the conversion will be much less expensive, and you can source your own parts. If you have a shop do the conversion it will not be cheap, and you'll want to compare the conversion cost to simply trading for a Ram.

 

[Bill Stockard]

I have a 2007 F550 with the 6.0 liter engine (approx 82,000 miles on it). I use it to pull a 18,000 lb GVWR 5th wheel toy hauler RV. Also, if it's more economical, can the 6.0 L engine be rebuilt or refurbished to provide greater reliability?

Evidently, your 6.0L had done better than most towing a heavy fifth wheel. I remember two 6.0L engines that were rebuilt and the problem areas were fixed; however, I don't remember the name of the shop or have a contact with those owners any more. IIRC the engine rebuild was done in an independent diesel shop in CA and the cost was around $6,000 (3 or 4 years ago prices). There are probably other independent diesel truck shops that have the knowledge and experience repairing the 6.0L's weak points since so many were sold in Ford trucks.

Bill

 

[JR]

As to the actual problem the factory intercooler clamps are junk you should probably replace them as preventative mainteance with a quality aftermarket clamp. I would get a boost gauge so you can verify your actual pressure, this will tell you if your being plauged by typical clamp issues or if the plate on the turbo is truly sticking which causes excessive boost conditions. The bit about the blades being too corroded doesnt seem right to me I could be wrong but I dont think they change pitch it's just a plate that opens up on the back side

 

[PDM]

Some interesting reading over on the Ford forum for a background education on 6.0 reliability issues and how to deal with them:
http://www.thedieselstop.com/forums/f21/how-much-bulletproofing-should-i-do-325449/
http://www.thedieselstop.com/forums/f23/2006-6-0l-384690/

Sounds like the mentioned weaknesses can cause what is essentially a "cascading failure". Reading the 2 threads is a quick education on what can happen, and what you can do to prevent problems. Looks like the 6.0 has only 4 head bolts per cylinder, so a recurrant overboost condition will eventually cause the head bolts to eventually yield resulting in head gasket failure, etc.

That said, If I had a running 6.0 I might invest the money in giving it a good chance at a long and trouble-free life. It may be the lowest cost solution.

 

[JR]

It is a shame you have to sink several thousand dollars into an engine just to make it reliable at OEM horsepower levels. I've got a buddy with an 05 6.0, he put an Edge programmer on and popped the headgasket within a month. I asked him where he had the fuel cut off set, he said 27 pounds of boost :-laf:-laf

 

[PDM]

Here is a backgrounder on "Bullet-Proofing the 6.0L PSD":
http://www.powerstroke.org/forum/ge...204386-write-up-bullet-proofing-6-0l-psd.html

 

[rscurtis]

That's an awful lot of work for a truck that was supposed to be "Built Ford Tough" from the factory.

 

[Joseph Donnelly]

You should get a good turbo shop to replace the bad wheel and precision re-balance. Then, I recommend you sell the truck while it is still running OK. Neither the 6.0, 6.4 or Ford 6.7 has had a good track record. That is just fact and you can surf the internet for verification.

 

[Wingate]

I would contact Destroked and see what they charge. YOu only need a stock CR engine. If you arent 4x4, it should be much less expensive. The call is free anyway. Short of that, IF it were me, and I was limited on funds, I would spend the money on a replacement turbo (maybe aftermarket) and an EGR delete kit, have it installed, cross your fingers and hope it holds on.

 

[S.Morris]

There is a shop in / near Tampa that deals only with Ford PS engines. I found with IT search last winter when BIL was having issues with his 07 6,0 a long way from home. He never did call the Tampa shop as he found a retired Ford guy who was very honest and made a good extra income working on Ford only PS. He worked for 35hr and knew his Fords.......a real find. Cost him 2000.00 to get fixed up and home to Barrie ONt.

Sold his 07 Ford SRW 3500 and bought a 07 DRW Ram for the money he got from the Ford. Ford had 55K miles , Ram has 110K miles.

 

[AEdelheit]

I know a few people with 6.0s that addressed there shortcomings and have good reliability for over 100k. Im not a fan of them but if your stuck with the truck putting some money into the engine should address reliability issues.

 

[stockplug]

Good mileage and power....BUT the head gaskets, egr system and sensors will most likely give you problems, and to do head gaskets they pull the cab off the truck... it will cost you...