After further reading and investigation, ya remove the throttle plate and clean the egr if its not deleted. See if that helps also when the place swapped engines did they change oil, filter, and fuel filter?

 

That's not correct at all. 03 had the loud whistling 10 vane turbos, 04-04.5 had 12 vanes and the 05+ had something like 13 or 15, I can't remember, cause no one cares about those. Everyone is after the 03 with the 10 vanes.

I've heard of that switch being bad and/or the plates sticking causing a major restriction in the air flow, thus running like poo. The throttle plate doesn't control RPM's anyways, fuel does, it's a diesel, not a gas job. A lot of guys just get rid of the early style intake elbow with the throttle plate and put in the newer 05+ intake elbow that is hollow.

Fuel controls RPM, you add fuel, RPM increases, power increases, the truck moves. Take fuel away, RPM drops, engine idles down or shuts off. We use air to cool our engines, not fuel like a gas truck. Take off an intercooler tube (cut air flow) and mat it, watch how fast your pyro flys up! (I wouldn't actually try this haha).

Does he not have access to a scanner to see what's going on? I have been less than impressed with most of the Ford diesel tech's I've encountered. I can count on my hand how many I would trust, and that's adding up everyone from the forums too.

This really needs to be put on a scanner to see what's going on. Can you give us some more symptoms? It's just low on power? Any smoke when you roll into it? Turbo boosting up like normal? How many miles were on this motor?

 

[QUOTE=Mdub707;841788]That's not correct at all. 03 had the loud whistling 10 vane turbos, 04-04.5 had 12 vanes and the 05+ had something like 13 or 15, I can't remember, cause no one cares about those. Everyone is after the 03 with the 10 vanes.

Sorry about that. Guess I wasn't so sure.



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No problem man, you were 1/2 right! I honestly can't remember how many vanes the 05+ had, I think it's 15.

I think they went 10 --> 12 --> 15

10 vanes are 03 for sure, they're the whistlers. So many customers complained about the noise, they changed them, or at least that's what I've heard. Obviously most of us here wouldn't fall into that category, since we want that turbo whistle!!!

 

Lol I just knew the 03 was the one all us fanatics were after!

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Exactly, and the 10 vanes on the exhaust side are the giveaway. I'd imagine some of them made it to 04 model year trucks too. So even if someone says it's off an 04, it may still be worth looking!

 

To add to the OP's original question, there are WAY more things different on these than just throttle plates.

Some of the things off the top of my head:
FICM's
Injectors
Injector hold downs
Rocker boxes
heads
pistons
harness'
The intake elbow as you are asking about
the intake manifold could be, depending on how early/late of an 04 it came out of
early 04 had the ICP in the back, the ICP and pigtail are notorious for failing due to oil dripping on them, 04.5+ had it moved to passenger side valve cover

My point is, there are a TON of differences and I've heard when swapping it's always best/easiest to find the same year motor. I'd be willing to be the PCM and such are all different too.

It may even be as simple as having the Ford dealer reflash the thing too... Just food for thought.

 

all the bolt on stuff off the 07 were put on the 04 motor, he used the long block only

 

Well I would consider the intake elbow a bolt on piece, so which one was used? The one from the 04 with the butterfly valve, or the one off the 07 without it?

It really should be hooked to a scanner. I'd think even a simple code reader at this point would help us get started at where to look.

 

that butterfly valve was put on there to promote more flow from the EGR valve but it didn't work as good as they thought, my truck is an early 04 and it didn't even have the butterfly plate in it, all the electrical hookups were dummies, I put a 05 up cfm intake on it. And yes my turbo whisles like a chain gang, my wife can hear me a half mile before I make it home. truck was built 8-03

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Sorry for getting a little off track;;

TO FIX THIS PROBLEM REMOVE THE SHORT INTAKE ELBO AND THE BUTTERFLY HOUSING
AND REPLACE WITH AN 05 AND UP TALLER INTAKE ELBOW, THE ONE OFF
THE 07 WILL WORK FINE.