2004 Mondeo Estate TDCi - Ford diagnostics indicate all ok, however large black pancake and black smoke when pulling away in second gear. There is no loss of power. Ford agents unable to identify any fault, injectors, filters, EGR etc all checked. Can anyone please advise if they have experienced similar and how it was rectified.

check the large intercooler pipe from the bottom of the egr valve for leaks, its the common cause of black smoke.