Got this truck about 18 months back, at 200k, now has 230k on it. When I bought it I did the EGR + oil cooler (flushed old), CAT coolant/filter, and any cheap seals I could find cause I didnt want to fool with it later.

2 months later it started a small leak down the back of the block, a small drop in the driveway every 2-3 days, year later it started leaking pretty bad, 6-8 drips everytime I park it. I have chased it hard, check IPR/ICP for leaks, changed the turbo drain tube.

This week changed the oil cooler gasket because I noticed a broken bolt on the cooler housing, sure enough the gasket was very marked and twisted in that spot, I replaced the broken bolt and got back on the road.

Couple days later, leaking again.

Cant tell where its coming from as the valley is just covered anytime I go in there, but now my last suspect is the HPOP, and I just dont know if its the HPOP cover gasket, or an internal pressure leak, I dont think its internal.

1. Running Torque Pro shows ~850psi cold idle pressure, 585 hot idle pressure.
2. Starts in under 3 seconds
3. Instant throttle response and great power.
4. No missing, never had a stall or no start issue in 30k miles

I am waiting for a fitting to come to do the ICP leak test, but am wondering what the 2003 has for potential leakage points in the HPOP, most everything I find is regarding newer models with STC fittings. If it was a pressure leak wouldnt I have no start issues, or show low pressures?

 

An internal leak has nothing to do with seeing oil on the driveway. Your ICP is right where it should be. You don't have a weak HPOP(other than the over all design).
The covers however, have been known to leak where the back cover joins up right there. One spot either side they used RTV. Check out this thread, Sean(Yahiko) has some good info there in post #8.
https://www.ford-trucks.com/forums/1...r-leaking.html
DO NOT cheap out on the gasket maker, get the OEM Ford stuff. Yes, it's WAY more than you need, and yes.......it beats the crap out of taking the cover off again when a cheaper brand does not seal it up. It's the TA 31 stuff from the dealer or wherever else you can get it.
Obviously it would be good to confirm this is where your leak is coming from, and it also begs the question...............would you be money/time ahead to just replace the HPOP while you have it all torn down? This is an early build, and it's a matter of IF, not WHEN.

 

Its a matter of WHEN, it will fail, not IF it will fail...IT WILL FAIL... period.

Mike needs another cup of coffee..

Makes it hard to justify a gasket replacement costing $1300 if you only have a leaking cover gasket. But if your there, cover off and staring at the thing with a couple bolts to remove, you should seriously consider a replacement pump. Diesel Site, Adrenaline Pump for 6.0 2003-2004 trucks makes a 24month warranty HO pump and they are killer. The OEM replacements have been know to fail out of the box, there's guaranties it to run out of the box.

 

Thus the result when you are fasting for a blood draw for work insurance purposes. Word the wise, don't post advice if you are fasting and low on caffeine

 

I'm accustomed to keeping my figure "Full", especially in the morning!

 

Ok, thanks for the tips. There is no RTV in my shop, only carry 3M products.