2003 BA Ford Falcon XR6T Sedan Manual
400rwkw w/ 770nm of torque @15psi Boost Tuned by Forced Performance
Runs on E85 , T56 Tremec 6-Speed manual , Externally Gated , Stock Bottom End , HP tuning software
Has all the go to mods injectors , surge tank , fuel pumps , intercooler , valves springs , backing plate and oil pump gears , dump pipe , exhaust , timing chain , guides , sprockets etc.
Hey Guys looking for any suggestions on what this issue may be?
FYI - Car was running completely normal before I changed the rocker cover gasket.
So a while ago I decided to replace my rocker cover gasket, everything went well. Went to go turn over the car and noticed there was a misfire when I gave it a little throttle, however it did idle fine. So I went and got new spark plugs and coils packs. Gapped all the plugs to the same that was in the car. Put them in and went to see how that went, still had the issue although when I give it a little bit of throttle (2500rpm) it would have a flat spot and would stall the car. When I give it a lot of throttle everything sounds fine but it can sometimes come back down to idle a little hesitant. Fuel pressure is fine and normal there are no signs of wiring damage.
Got it on a tow truck and took it to the mechanics. They supplied, re-gapped and fitted new spark plugs that were the same as the originals. Checked for flat spot at low RPM. Connected diagnostic tool and checked for fault codes - numerous evident (some may have been altered in tune). Checked live data, checked throttle position sensor, checked for vac leaks and unable to locate cause of problem. Suggest going into vehicle dyno and having tune checked. Is what they told me.
So I then took it home and decided to self diagnose it myself and see what I might find. Just in case, before I take it to the Tuners.
I found the following- PCV blocked, Exhaust manifold gasket blown, exhaust manifold missing nuts with loose studs, camshaft position sensor cracked, CHRA shaft play and making sounds, oil feed line factory and needed replacing, oil temp sensor snapped, VCT solenoids barely opening, hair pin cracks throughout turbine housing and the battery was on its last legs.
Since this issue I have replaced everything new without cutting corners. I have bought and fitted a new GTX3582R Gen2, new gaskets, studs and nuts on exhaust manifold and turbo, braided oil feed line, throttle body gasket, VCT solenoids, Boost control solenoid, turbine housing, PCV valve, Idler pulleys, Hose clamps,
Camshaft position sensors (Intake and Exhaust), Coolant temp sensor, Fuel filter,
I have primed the new turbo and got it going again. The e85 in the tank is about 6months old now. Everything is working properly and sounds great on idle, especially from the new VCT solenoids. Car is running a lot better then what it was originally, although the flat spot has gotten less aggressive which makes the car stalls less when giving it a little rev. I know, I need to take it in and get it tuned from the new turbo but does anyone have any idea at what this could be? Ive searched all the forums but cant seem to locate the exact issue. The last time the car was put on a dyno would have to be a little over a year ago.
Thanks for reading.
Kind Regards,
Robbie
