I can answer any questions that you might have if you want to call me at 763-786-6429The gentleman at dieselorings.com was also very helpful.
Ford says that the underneath plug is unserviceable, I serviced it just fine with some care. No problems, no leaks. International harvester makes a kit to service the hpop for all plugs. Although I did not use it, I picked it up just in case because the plug in that kit is slightly longer to gain more threads. I still have that kit#1842906C92 from international harvester. The instructions are the same as on the above links. I will be returning it to my Ford dealer when I can get there. The kit also has the instructions to repair the hpop (same instructions as the above links).
To remove the hpop, remove the front oil resevoir to access the hpop drive gear. remove the inspection plate from in front to get at the gear bolt. Once the gear is removed and the lines are removed you gain access to be able to unbolt the hpop from the backside. It has been a while so if you have additional questions I can be more specific, just call. Good luck.Mark
So all these instructions say to not lose this this ball inside the non-servicable plug hole. Has anybody seen it? If so what's it look like? I'm in the process of repairing a hpop on a 96, but don't see the ball anywhere. Checked on a spare pump and was really careful removing the plug and didn't see the ball in there either.
Any help?
Bob???
Don't want to reinstall if it's jacked up.
Thanks!
__________________ 02 F350 CC Dually 4x4 118K; Forged rods; headstuds; Tymar; coolant filter; 200 Amp alt; AIH Delete; Prepump/tank mods; 5" exhaust; IDM-140; x-monitor; Leveling kit; 06 leather seats f/r; 07 upfitters; custom dash; KR boards; rhinoed - FOR SALE 95 F350 CC Dually psd auto; Tymar Intake; 3" DP; Straight piped; Western Hauler - soon to be worked over...
It's in there. When removing the plug when the truck in mounted on the engine, the flow of oil out of the hole usually takes the ball with it.
If you remove the pump from the truck as you are supposed to, the oil in the pump gets drained before you remove the plug and surface tension of the oil will usually hold it in place in it's machined recess in the front body of the pump, just forward of where the rod on the non-serviceable plug sits. If you have a small plastic/rubber hammer, tapping on the HPOP can sometimes dislodge it but it could fly out of the IPR opening or the plug opening. I just removed this ball from a pump I got from mudmaker and it was cold in the shop. Oil surface tension would not release it. I ended up blowing it out with a little air pressure into the small hole on the front machined area of the HPOP.
It is a plastic (or nylon) ball, exactly .25" in diameter.
Thank you Bob. That helps a bunch!! I was thinking it was in the bottom of the plug hole. That would explain why I didn't see it in either pump. I removed the pump from the truck before taking the plug out, so I bet it still in there.
I'll check further tonight!
__________________ 02 F350 CC Dually 4x4 118K; Forged rods; headstuds; Tymar; coolant filter; 200 Amp alt; AIH Delete; Prepump/tank mods; 5" exhaust; IDM-140; x-monitor; Leveling kit; 06 leather seats f/r; 07 upfitters; custom dash; KR boards; rhinoed - FOR SALE 95 F350 CC Dually psd auto; Tymar Intake; 3" DP; Straight piped; Western Hauler - soon to be worked over...
If you have the hpop positioned as they instruct you to when you remove that plug you will not see the ball and it can't come out because gravity holds it in. I knew it did not fall out when I did mine because the plug lifted straight out, no ball came with it. I, then serviced the plug with new o-ring and reset the plug and I never saw the ball.
Giood luck
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