i'm driving a volvo 06 with isx475 , all i did is egr plug disconnected, little welding performance ,met illinois diesel doctor to get this thing to be full open ...that's it!!!! power great ,pulling great couldn't be better

2006 International 9900I, ISX 475, 13 speed overdrive, 3:73 rears on small rubber
Problem: Intermitent when engine at operating temp. low power, occasional EGR bark, high water temp (210 F), fan comes on at 190 F for 2 seconds, 200 F for 1 or 2 seconds and 210 F for almost 25 seconds. continuous black smoke while pulling under load in top 2 gears, fuel milage at high 4s to low 5 mpg

When parked running A/C at operating temp, flashing warning lights(high water temp, low oil pressure etc), beeping consistant, ALL gauges pinning themselves to max limits including (voltage, oil pressure,water temp, tach and speedo)

Replaced 2 EGR valves, exhaust temp sensor ,removed and cleaned exhaust pressure tubes along with the air intake horn, removed as many electrical plugs as I could get at , cleaned with electronic contact cleaner and applied dielectric grease.

Conclution; Can't decide if I should throw more money into it having certified technicians guess at the problem or just yank it out and drop in a N-14 and use my ISX for a good boat anchor.

What do you all think ?

pull the air actuator off of the turbo and see if the sector shaft moves freely up and down. if it feels like it has tension on it or is stuck you need a new turbo. common problem with black smoke under a pull. as far as the other weird things...if you have a test ecm available i would try that and see what happens.

Originally Posted by rbelinger

2006 International 9900I, ISX 475, 13 speed overdrive, 3:73 rears on small rubber
Problem: Intermitent when engine at operating temp. low power, occasional EGR bark, high water temp (210 F), fan comes on at 190 F for 2 seconds, 200 F for 1 or 2 seconds and 210 F for almost 25 seconds. continuous black smoke while pulling under load in top 2 gears, fuel milage at high 4s to low 5 mpg

When parked running A/C at operating temp, flashing warning lights(high water temp, low oil pressure etc), beeping consistant, ALL gauges pinning themselves to max limits including (voltage, oil pressure,water temp, tach and speedo)

Replaced 2 EGR valves, exhaust temp sensor ,removed and cleaned exhaust pressure tubes along with the air intake horn, removed as many electrical plugs as I could get at , cleaned with electronic contact cleaner and applied dielectric grease.

Conclution; Can't decide if I should throw more money into it having certified technicians guess at the problem or just yank it out and drop in a N-14 and use my ISX for a good boat anchor.

What do you all think ?

Do you let the turbo cool down before shutting it off?

This truck should pull with that motor and those gears.. The turbos in this motor stick and it sounds like that is what it doing to you! Ask cummins for policy on it ! They should help you out ! Good luck!

Originally Posted by bdmose

I don't know who to blame, the mechanics at KW/Cummins or the ISX. My truck is in the shop getting its 5th turbo...........Obviously something else is wrong and the "code readers"/"mechanics" are just replacing 1 after another without finding the true problem. I have an 07 t2000, I believe this was the first year they put the Regen system on. Has anyone else had that many problems with ANY truck they have ever driven?

Well, I'm sorry to say this, but you have about the worst truck spec wise for having major issues. The early T2000's were nightmares with the new regen, and it's the same way with the ISX. I sold many of these trucks before the problems slowly started overwhelming Paccar dealers. Personally, after having this many turbos, etc. I would be getting a different truck. Try a new KW T660.

I have a Volvo 780 with cummins isx 450. I had all problems described above until I just turned the EGR off. Now is running better, it gets good fuel mileage 6.8-7.2 average.