Variable Vanes Inside Turbo Seize Due to Carbon Buildup on Ford F-350 Super Duty

Problem Description and Possible Solution

It is common to see the variable vanes inside the turbo seize or bind from carbon buildup. This causes an overboost or underboost condition when driving.

Problem Data
RepairPal Verified
Average mileage: 52,918 (31,200–80,000)
Engine affected: 6.0L V8 Diesel Turbo
5 model years affected: 2003, 2004, 2005, 2006, more2007
13 people reported this problem
Viewing 1 - 6 of 6 problem details
Engine light came on.Was told that the turbo vanes were rusty and that they needed cleaned. Cost me $800.00 to get it repaired
Was told my turbo veins were rusty and that it needed to be removed and cleaned. Cost me 950 dollars to get done by ford dealer.
Replaced turbo at 40,000, now it's bad again at 48,000. Worst truck ever. Injector failure, fuel tank delaminated, oil pan rusted out, all before 45,000 miles.
Computer began to trip Check Engine Light with P0299 code. Trip typically occurred upon start up per engine parameters displayed on code reader. Engine operated/performed fine despite code. Intermittently when the engine was somewhat cold (within the first 10 minutes of operation), if following a moderate application of throttle, the throttle was rapidly closed, the engine would make a 2 to 3 second "BA BA BA BA Ba Ba Ba ba ba" sound varying in pitch over the duration from high to low and increasing in time interval between "Ba"s. It sounded like a hinged plastic door cycling from open to closed to open to closed, decreasing in volume and frequency over a 2 to 3 second period immediately following coming off of the throttle. Smog check immanent which requires Check Engine Light not to be displayed. Dealership charged approx. $2200+ plus original turbo core for turbo replacement (probably with a reconditioned turbo). Turbo replacement warrantied for only 2 years. Ford should cover the costs for repairs required by their defective design beyond the 5 year point as the vehicle only had 43000 miles on it when the problem became evident and a turbo should certainly last longer than 43000 miles.
Turbo charger had to be cleaned we were on vacation in Florida
Experienced a decrease in power. Much hesitation as well
Had to bring vechile to Duncan Ford
In key west
Truck sits for weeks at a time before being used. Sometimes the turbo doesn't work at all for miles then kicks in. Other times I get an overboost condition that sets off an overboost code.

Must be carbon buildup in the turbo vanes and/or EGR valve according to what I've read. Wish someone would post how much trouble it is to take care of yourself.