Excessive soot buildup in maxxforce engines

Hello everyone, I'm new here, please forgive me if this thread is in the wrong place, anyway, here's what im dealing with.
We have a customer that has 4 international durastar box trucks with the maxxforce dt engine. They are at about 200k miles. Ive been fighting regen frequency as well as boost pressure dtcs.
What are the normal boost readings at WOT while parked and under load? I disassembled one this week, the egr cooler was completely clogged, the hp turbo showed indications of oil passing through, with compressor wheel play, contacting the housing. The crankcase filter is new. Replaced the egr cooler, both turbos, had the dpf, doc, and cac cleaned. The cac was pressure tested, good. I also have replaced the aft injector. Parked at WOT im reading between 9 to 10 psi of boost. Truck seems to run fine now, im just wanting to see what all you guys have ran into with these sooty ########.
Any advice, insight and tips would be greatly appreciated. Thanks guys!

 

Since you’ve got 4 trucks with Maxxforce, you’ll need 4 of these.

 

Wish it was that easy lol. They want them fixed. Im hoping to keep them rolling for the guy.

 

You have replaced most of the problem parts and well on your way to keeping them on the road. WOT no load spec is 10, so you are good there. On the road under full load your boost should hit 32-36 psi.

 

I’m assuming this is a 2010 emmisions truck since you said cooler not coolerS. Replace IMP sensor if you haven’t already, if the cooler was clogged it’s on it’s way to being clogged as well. I haven’t had luck with cleaning them personally. I just have to replace them the next week. I would also recommend an open crankcase conversion to prevent turbo coking (if the serial number is eligible) I can check for you if you don’t have navistar service portal access if you send me last 8 of the vin. I would also be curious to know what your Regen temps are as well as TC1TOP pressure is, have you replaced the BCS tubes? They break all the time.

 

Thanks for the responses fellas. The truck is a 14, I also replaced the IMP sensor. Am i missing a second egr cooler? If so, where is it? And forgive me, what are BCS tubes? Regen temps were between 900 to 1100, Tc1top reading was 1.2 to 1.5 psi i believe. I'll post the vin when i get back to the shop tomorrow morning, problem is my service manager just had me replace the crankcase filter on all four. He likely won't let me delete them just yet.
Thanks for the help, im trying to learn on the fly with these trucks. Ill get more accurate readings asap as well. Thanks again fellas.

 

Only 07 emmisons have 2 EGR coolerS
If you do open conversion it doesn’t delete the crankcase filter, just the plumbing for it. Some come with a different valve cover there are baffled and none baffled. You have to check which one it is to get the right kit for conversion there are several different ones some even come with a ECM. I have only seen a few engine serial numbers that aren’t allowed to open convert. They where all on buses though I believe

 

Do you mean N13? Or do you mean Maxxfor e 11l or 9l? A lot of people still call anything Navistar a Maxxforce even if it’s not Maxxforce.

 

Ok, thanks Navtech. Curious, where does the conversion kit route the oil drains on the turbos?

 

The scan tool lists it as maxxforce dt/9/10. Im unfamiliar with them, sorry.