I have a 03 F250 superduty 6.0 when driving it cuts out and puffs black smoke,the boostgage maxes out, its been in the shop twice first time they changed fuelpump second time they changed EGR, MAP sensor, ICP sensor, it still does it every now and then. What else can this be?

This link may help:

https://www.askmehelpdesk.com/cars-t...ml#post1977241

Be sure and only use SAE 5W-40 full synthetic heavy duty diesel engine oil in your PSD. Only use Motorcraft oil and air filters. This link will further amplify this:

https://www.askmehelpdesk.com/cars-t...ml#post1415281

I use what oil the ford dealer puts in it

You don't want to go that route. Tell your Ford dealer to use Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil.

The first link clearly indicates that your black smoke is due to too much unburned fuel being blown out the exhaust. It is usually due to restricted air flow (inlet/exhaust restriction or dirty air filter) or engine overload. Restricted air flow problems should be pretty straight-forward to solve. Ford has warned repeatedly that not using Motorcraft air filters can adversely restrict air flow and even damage turbo blades. Engine overload issues can be, however, trickier to solve.

Even though you did not mention it, I suspect you may have installed a power chip, causing engine overload (boost gauge maxing out), black smoke, and engine shut down. I recommend using the standard OEM chip. On a diesel engine, injecting more fuel will result in more power--up to a certain point. This is almost the opposite of a gasoline engine where adding fuel and richening the mixture excessively will kill performance and lower power. A diesel engine is different. As you add more fuel and richen the mixture, power output will continue to climb until the point that there is so much fuel that much of it is unburned (or partially burned black smoke) and then the power increase will taper off. Before the power increase drops off dramatically, you'll be facing another limiting factor--exhaust gas temperature (EGT). Adding more fuel makes more power, but it also raises EGT. If you add too much fuel and exhaust gas temperatures get too hot, then you can seriously damage your engine. Hence, the suggestion to only use synthetic HDDO. This is the best way to protect the turbo and the engine from excess heat and pressure, due to engine overload.

WhiteTrash, since you don't have much experience with diesels, this is all new to you. You bought the most problematic diesel engine Ford has ever made, from the worst 3 years in the life of the 6.0 (2003 to 2005). Many of us, with a great deal of experience with diesels, have seen bad black smoke issues completely clear up just by switching to full synthetic HDDO. We have also seen PSD fuel pressure problems solved by using synthetics. Read about the condition of the oil affecting Injector Control Pressure in the link. It's a fact that turbos, diesel engines, and transmissions simply perform better and last longer with synthetics. Research it and then try it for yourself--don't just use whatever the dealer suggests. They have an interest in your PSD breaking down and not lasting long. If you want to continue having problems with your diesel, stick to your current program. The links had everything to do with your problem. End of story.