I've got both rails off my truck right now, and I'm about to replace all of the nipple cups and o-rings for the rails, as well as all of the injector o-rings, including the top o-ring. Several injectors have o-rings that are shredded and just in terrible shape.

The problem is I noticed on the site of the shop I bought the cups and o-ring from, they're not meant for anything earlier than the 2004.25 oil rails, which I'm assuming is the start of the wavy rail.

I already replaced one to see if there was a difference, and the only thing I can tell is that the neck on the nipple side that goes into the injector is just a tad longer than the OEM cups. I'll try to get a photo of it in a minute to show the difference.

Has anyone with the log rail replace their cups, and if so, have you had any issues? I just dropped close to 400 bucks for all these o-rings, and I'd really like to be able to use them and have peace of mind that the HPO system is sealed up.

 

I don't have an answer for you, but am curious if you could use old nipple cup with the new o-ring???

Why do they have to be replaced?

 

A couple of them are showing signs of high pressure oil leakage from the oil rail. The small end of the cup has severe wear on a couple of them. I figure since I've got the thing torn apart, I may as well replace whatever I can while I'm in there. I just finished doing both rails with the new cups and o-rings, so we'll see how it goes.

On a positive note, I managed to pull half the injectors out and remove the stupid clips from the top o-ring. What a pain in the @$#%* that is!! I found using a sharp punch made it much easier than mucking with two screwdrivers. The other o-rings on the injectors were hosed as well. Shredded and coming apart in strands. Really glad I decided to replace them all.

 

Wow, I had no idea the nipples would see wear from the hpo! Good luck, hope you get it figured out...

 

I didn't quite understand it either, but if you read this thread it explains it. All of the top o-rings on mine looked good except one on cylinder 7. I figured I had everything opened up, and it wasn't really awfully expensive, so just go ahead and do it.

https://www.ford-trucks.com/forums/1...ole-story.html

Apparently it's more common on the 04 and up engines with the wavy oil rail. I have the old style log shaped oil rail, and even though the parts say they're not for anything before the 04 engine, it worked fine on mine and sealed up with no problems. Getting the clip out to replace the o-ring is a bear, but I came up with a method that worked well for me.

I took a tiny, sharp flathead screwdriver and pried the o-ring out first, then pushed the metal retaining ring down all the day. This gives you some clearance to take a sharp punch with a flat tip about a .5-1 mm in diameter and hit the end of the clip and work one edge around about 1/4 of the way. This pushes the edge of the clip out of the groove and down, then you can take the small flathead and just pry it out. Once I got that method down, it took me about 15 minutes to do 4 injector, whereas the night before it took me about an hour to get through 3 of them.

 

wait.. there are o-rings at the top of the injector too?


great, guess I need to remove my injectors again and check this.

 

Injector o-ring kits from Ford do not come with the upper o-ring. You have to get kits from alliant or similar vendors to get that extra oring. Here is a link to the ones I got when I did mine.
http://www.ebay.com/itm/FORD-POWERSTROKE-INJECTOR-O-RING-KIT-6-0L-8-SETS-AP002-3C3Z-9229-AA-CM5055-/190779520944?pt=Motors_Car_Truck_Parts_Accessories&hash=item2c6b5877b0&vxp=mtr

 

Man! I read nipple and got all excited!

 

well those rails don't have much problems But your seeing the wear on the metal Cup itself??

How about the Push rods now would be a good time to upgate them


I know your trucks been down awhile so why was it down??? Sounds like maybe Low HPO????????

 

Yes there is

 

What's up with the push rods? You mean to install the 6.4 rods in it?

It was down just for an injector, but my second son came along and other things, mostly time and money, kept me from getting it fixed. I took the downtime to rebuild the turbo and fix a few other items on it while it wasn't running. I had one injector that wouldn't hold vacuum at all, and then I had two on the driver side that had bad copper seals and the o-rings were shredded from the blowby.

Edit: Oh, and yes, the smaller end that went into the injector was badly worn on cylinder 7, and sure enough the top o-ring was torn up a bit. It looked just like the one in the thread about fixing the cups that's in the tech folder. That's the one that had the bad o-ring in the oil rail, so I just went ahead and fixed them all.