We recently performed work for a customer from Buckley, WA. The vehicle in question was a 1999 Ford F250 7.3L PowerStroke with an automatic transmission and 4wd. The customer came to us to have a performance evaluation done on his truck because he was preparing to take a trip and planning to tow a 35’ 5^th wheel trailer. He felt that the truck ran fine and stated that he did already have a Banks PowerPack system on the truck.  He just wanted to be sure that all was ok for his trip.

To provide the Performance Evaluation we did the needed labor to test-drive the truck to see how it performed in the real world. Performance was not what we would have expected from a truck that already had a BANKS PowerPack system installed. Back at the shop, we scanned the PCM (Computer) for codes, tested for exhaust and intake (boost) leaks and made sure we had good fuel supply. We performed a backpressure test and listened with a stethoscope for any audible exhaust leaks at exhaust manifolds, turbo and turbo y-pipe connections.  A pressurized boost leak test was done and we checked the condition of the Turbo compressor wheel at that time.

Once finished with the check out our technician noted his findings as follows:

Did testing and inspection to note the following issues.  The K&N filter was found to be installed incorrectly.  The index tabs on the side of the filter element were not properly lined up with the housing because the filter was rotated 180 degrees from the proper orientation. The correct filter for the housing had been installed incorrectly, causing dirt to bypass the air filter. The turbo compressor wheel was damaged with small nicks on lead edges of blades caused by dirt particles bypassing the air filter.  Turbo shaft bearing play was minimal indicating the bearing condition to be good.  Would consider the turbo ok for continued use but should be monitored to make sure no more dirt gets past the air filter and that the compressor wheel does not deteriorate further. The OEM intake system should be upgraded with the upgraded later model Ford intake system (See TSB) or a new aftermarket system, permitting better air flow and eliminating the poorly designed intake housing Ford used on early 1999 production pickup trucks.  Truck is also equipped with the early OEM style radiator with no transmission cooler section.  The PowerShop has seen multiple cases of shortened trans life from towing heavy loads with the early style radiator system caused by overheating. 

In regards to the PowerPack installed by another shop, our technician noted his findings as follows:

Heat shielding on the driver’s side intercooler tube is being held on with plastic tie wraps (which will melt) and should have been secured with the provided metal hose clamps from the BANKS kit.  The exhaust system was not properly supported which resulted in the Banks muffler developing fractures at the front weld seam resulting in an exhaust leak. The exhaust should have had a hanger style clamp at inlet of the muffler for better support as provided and instructed with the BANKS kit.  The exhaust system moved and flexed too much under load and caused the muffler to fail.  No “zeener diode” is installed on the MAP sensor signal wire.  The turbo wastegate was also found to be misadjusted so that max boost was only 16psi rather than the normal 25psi for a PowerPack equipped truck.  The pyrometer probe is installed in the down pipe.  (should be in the more accurate hot side location)  1200 + degrees on the EGT gauge was reported by the customer when towing.  Further use at this cold side temperature will result in severe engine damage.

Highly recommend moving thermocouple to hot side of turbo especially if towing on a regular basis.

Recommendations:

Dyno testing before & after repairs to validate the improvement made.

Install Zeener diode as recommended by Banks to stop high boost codes when wastegate is adjusted properly.

Adjust wastegate to provide Banks intended boost levels.  Running boost at the proper level will keep EGT’s cooler and make the engine more efficient.

AFE intake system upgrade to stop further dirt entry to the engine and improve intake airflow dramatically and also result in better power and cooler exhaust temps.

Install Ford recommended radiator upgrade with supplemental transmission cooling to extend transmission life.

Transmission cooler bypass delete. (The transcooler bypass is a component Ford installed to cause already failed transmissions to not be damaged as badly as without the tube.  The bypass tubes would be ok if they were dependable but as the tube check valves age they are failing in great numbers and becoming the cause of transmission failures rather than provide a benefit.)

Move pyrometer probe to hot side of turbo for more accurate readings.

Install correct clamps on intercooler tube heat shield instead of plastic tie wraps.

Replace Banks muffler

Install missing hanger on exhaust

Results of Work Performed:

The customer did decide to have the entire list of recommended repairs performed.  He reported back to us that his wife drove the truck and noticed the power to be a lot better than before the work was done.  In his opinion the power was what he expected from a PowerPack equipped vehicle and the engine runs quieter than before. "Now, it is a really nice running truck."

(See the picture below showing the cracked Banks muffler and be sure to click on the link to view the before and after dyno results.