Yes. We kept everything clean around the fuel lines and double checked them prior to putting everything back together. Ford checked the fuel return and found metal shavings coating it.

I'm sorry to hear that. Does this mean a full fuel system replacement? Or too early to tell?

Full replacement

Wow...So sorry to hear about that, but I know your pain to an extent. When I did my delete, I took out a fuel injector, and the whole fuel return line assembly. Found out when I turned the truck on it was leaking like crazy. White Bear Lake Ford Parts is your friend. The HPFP is 4k from them. They charge what it costs them plus 10%. For both my injector and fuel return line assembly it was cheaper to buy and overnight it then it was to buy from the local dealership. Let us know how you end up and take pictures. Also keep any parts you have to pay for and take pictures. I want to know why the pump can't be rebuilt.

right now I am just waiting for hear back from the insurance adjuster to find out if they will cover it.

pump can't be rebuilt as the pistons have scored the walls sending shavings through the system.

I think it is just a paperweight now. They have to melt it down and make another.

What Scott said! Nobody is into overboring these things and making larger pistons for them. When the pump loses lubrication either from fuel starvation or water in fuel, it takes no time at all for the tight tolerances inside the pump to cause enough friction to destroy the pump body. Think of an engine block that would have to be bored 0.250" to clean up the cylinders but nobody makes a piston bigger than 0.125".

Ouch!! That cost of a new fuel system has gotta hurt.

Waiting to hear about the performance gains though.

Sorry to hear of the loss of the fuel system...I hope the insurance company helps you out!

Sorry to hear about your troubles.

How long did you try to start it after the install? Are these hpfp's that fragile?!

What would have been the proper way to prime the system after you removed the fuel lines?

Thanks guys and the truck ran for about 4 seconds before she died. I primed the system got it started again but then it almost immediately died. Given that the fuel lines were cover, I don't know if an air void did it (as i forgot to purge the lines) or if I accidentally got water in it somehow. I tried starting it for about 20 mins before the truck stopped doing anything. The HPFP only likes good clean diesel anything else and they quit.

What is the proper purging technique? Do you just crack the line at the rail and let the electric pump push fuel to there?

So this problem I can see reoccurring in the future just like the older Cummins. When the lift pump pukes, the HPFP gets fried. The Cummins guys would put a pressure switch into their HPFP supply line that would turn on a light when the lift pump puked. Are we all wanting to do this too or does the computer monitor the lift pump pressure and shut the truck down when the lift pump pukes?

Ouch
 

Sorry to hear. I hope it works out for you. Did you run the pump dry and then continued to crank the system.

Yeah what about the injectors.

to reprime the system you just cycle the key 6 times, 30 seconds each and it will take care of any air voids. I don't know if I killed it with a dry pump pump or if some type of contaminate got in there. It needs the entire fuel system replaced injectors and all. Metal shavings found in the fuel return line so if I messed something up I did it in spades.

For lift pump monitoring I honestly don't know. When I get it back I am going to look into an AirDog II with pressure gauge just in the off chance water made it past the factory separator. Small chance I know but I am looking for piece of mind.