I was at the dealer this morning and saw one of the mechanics. I asked him about the 600 and if he thought it was "normal" for the clatter and he said no. Also I had him look up the TSB for the "white smoke/hesitation" problem and I saw where it said if your build date was from 12-10-03 to 02-02-04 then you would need this reflash. I am trying to figure out if these early build dates are the only ones with mileage problems. I am also thinking that the "hold time" on several new trucks that were on order was partly to cure this problem.
I am going to the dealer tomorrow with the following problems:
1. White smoke/hesitation reflash.
2. Excessive clatter.
3. Poor fuel mileage.

Service man said it sounds like possible bad injector (s).

 

Had same problems as you. After 4 service attempts I sent in the lemon card. The District Manager called and set up final(5th.) attempt. Tech. eng. was waiting on me when I arrived. He drove the truck for 5 min. and Fed.-exed 6 new injectors overnite. Problems fixed! Fuel mileage up 3-4mpg. , Miss / white smoke gone , clatter reduced (but not gone). Now , at moderate-WOT , the black SMOKE will ROLL. I still don't think things are 100% right , but its alot better.

 

A stock, brand new engine is not supposed to smoke.

This clatter is interesting. Has anyone that experiences this ever driven an 03 or early o4, non 600, to compare?

Both my 03's have slight clatter, for a second or two, under hard accel. BUt I consider it perfectly normal.

 

What is your MPG upto?

 

Mymaur,
I personally have driven two '04 models with 305/555 eng. I noticed no sound at all like the clatter that I hear with mine. I did notice that the normal sound of the diesel was a little louder than the 600. I also noticed that the overhead readout showed about 4mpg higher than mine and I had reset them both using the same stretch of road. There is definetly something "different" about my truck...I just hope they do something about it.

 

dwhite,

I read quite a few remarks about the clatter. Must be very annoying.

I think I am going to go see my buddy at my dealer and drive one of these 600's. Just to get a feel for what everyone is experiencing.

Hope they get it fixed.

 

Black smoke rolling????? That doesn't seem normal either. Maybe the new injectors were hopped up!

Those first 600s must have had a few issues. I know mine did. But as far as the clatter goes I think it was normal. At least on mine. Only happened at low throttle under load. Sounded very similar to pinging in a gasoline engine.

dwhite.....I understand your frustration! I hope they get your truck shaped up for you.

 

JMO, but if your pushing black smoke under moderate acceleration take it back there is something wrong there. The 600 is a moderatly quiet engine just like the 03s except for the "pinging" which is normal for the 600 engine.

 

That s exactly what my 03's do. They clatter under a load or hard acceleration. I consider it normal since both have done it.

Sounds like what dwhite is experiencing is something completely different. I've read other posts about this clatter issue.