Abnormal exhaust noise on 02-05 Ford 6.0L Diesel Engines is a growing concern, as these engines become older.
Consequently, many of these engines would fail inspections. Because, of exhaust noise.
Most often caused by cracked up-pipe bellows, loose turbo-to-up-pipe clamps, or a stuck (VGT) turbo actuator.
So, an engine that has abnormal exhaust noise usually signals an issue with either:
- The exhaust system
- Lubrication problems
- A failing mechanical component
Common Causes of Abnormal Exhaust Noise
Cracked Up-Pipe Bellows:
The flexible joint sections (bellows) on the factory up-pipes crack or tear under thermal stress. Then creates a loud high-pitched whistle, a rushing air sound, or an exhaust leak smell under the hood.
Loose or Misaligned Turbo Clamp:
The clamp connecting the up-pipes to the turbine inlet works loose or gets misaligned during service. As a result, causing a sharp hissing, abnormal exhaust noise or squealing noise under acceleration.
Stuck VGT Vanes:
Soot and carbon buildup bind the variable geometry turbo (VGT) unison ring. As a result, causing a loud roaring jet-engine sound or the loss of normal turbo pitch changes.
However, We Are Going To Talk About Exhaust Manifold Leaks
So, the source of this noise is coming from, between the exhaust manifold, and the cylinder head. Consequently, this engine never did have an exhaust manifold gasket from the factory.
However, abnormal exhaust noise, can be cured by installing a new gasket, made for this purpose.
Abnormal Exhaust Noise On, 02-05 Ford 6.0L Diesel Engines
So, there have been a whole list of changes, and upgrades with this new engine. But, not all of them are positive.
Unique, would be a good way to describe it:
- Now the engine size, is smaller.
- The crankshaft stroke increased, compared to the 7.3L.
- The cylinder bore size decreased, compared to the 7.3L.
Many of the changes include:
- New exhaust manifold gaskets have been made, to solve abnormal exhaust noise.
- Different engine gear train
- Cylinder head upgrades
- Turbo
- Injectors
- HPOP oiling system
- Even more sensors and actuators
- (EGR) cooler and (EGR) valve
So, for most applications, improvements usually come from cylinder head upgrades. As a result, the cylinder head was improved. Now having, four valves per cylinder. Also, there are two intake valves, each measuring 1.33” and two exhaust valves each measuring 1.10”.
Hence, the reason for the “twisted” position, was to help introduce, swirl into the combustion chamber.
So, the higher the port swirl is in the combustion chamber, the more efficiently diesel fuel will ignite. Therefore, reducing the “knocking” sound, that older diesel engines produced. And, abnormal exhaust noise.
The End Result Is A Quieter Engine, That Makes Other Noises Come To Life.
So, the abnormal exhaust noise, can easily be solved by installing a gasket. But, you would need to send the manifolds, to your local machine shop to be resurfaced. And, mechanical problems, do require more labor.
So, to solve this problem, a exhaust manifold gasket, was made by the manufacture. And, that lead to aftermarket suppliers, jumping in to help.
Some that have joined the list include:
- OEM # 1855240C1
- Felpro # MS96833
- Victor # MS19312
To help cure abnormal exhaust noise, this same gasket also fits:
- F-450 Super Duty 2007, 2003
- Excursion 2005, 2003
- F-250 Super Duty 2007, 2003
- E-450 Super Duty 2010, 2004
- E-350 Club Wagon 2005, 2004
- F-550 Super Duty 2007, 2003
- F-350 Super Duty 2007, 2003
- E-350 Super Duty 2010, 2004
Conclusion
Finally, other issues with the 6.0 diesel engine are said to include:
- Damaged injectors
- Necessary turbocharger replacements
- Exhaust noise
- Exhaust smoke
- And, other frequent breakdowns
So, engine performance issues, are another symptom that can be caused, by a problematic exhaust manifold. Consequently, if the exhaust manifold cracks or leaks, it can cause an exhaust leak. And, that can negatively affect engine performance.
As well as, contribute to abnormal exhaust noise. Finally, an exhaust leak, can cause the vehicle to experience a reduction in power, acceleration, and even fuel efficiency.
