I had checked the oil recently and saw it was a little less than one quart down.
Had planned to change soon so didn't top it.

Sunday started fine and was going well.
Air temp about 80, ran about 60 miles at highway speeds.
Started hearing what sounded like a missing 6637 air filter, kind'a had that low rumbling.
Came to a stop light and it was running a little rough, so I slipped it into neutral and kept the RPM up to about 1200.
Left the light and a cloud of blue smoke came out the rear.
Ran a little rough but speed was picking up.
Still heard that low rumbling sound.
Got about a half mile down and a big cloud of blue smoke and the engine chugged and died.

No idiot lights except for the check engine, useless gauges read normal.
Popped the hood and the engine was soaked with oil, mainly on the driver side. The chassis and tailgate, along with the cap rear window had a layer of oil on it. I discovered that when I went in the cap for a roll of paper towels.

There was a puddle of oil in the engine valley, fuel filter cap, basically everywhere it could spray.
It "seems" like it originated from just behind the alternator.
Checked the oil and it didn't show on the stick.
I had someone bring me six gallons of oil, just in case I needed it to get home.

It took 11, yes, ELEVEN quarts to bring the level to the top of the operating range on the stick.
It had been about 90 minutes since the event, cooled down a bit and it started right up. I heard that low rumbling sound for about 20 seconds, then all seemed well.
I looked all over the engine and underneath and found no new oil anywhere.
All looked ok, so I left.

Made the rest of the trip, just 15 miles, and checked the oil again.
It looked about one quart over full, so I removed one quart.
Several hours later, made the trip home, 90 miles with one stop to check oil. Level was good, no leaks.

Monday, I changed the 6637 air filter, it was dirty, pulled the cold pipe that goes down the driver side to the side of the radiator and removed the nasty foil. Been wanting to do that for years. Removed the battery box, cleaned underneath, was free of oil. Did a cut in the box so I can change the headlight more easily. Oh, and changed oil filter.

I cleaned everything all the way down and waited for it to dry.
Oil level was at the top of the range.
Started up fine, checked for leaks at idle and 1500 RPM.
Nothing found.

Made a 200 mile round trip yesterday with no issues.
Ran fine, no leaks, oil level right where it was.

So, any ideas what could have happened?

 

HPOP line o-ring unseated, then seated itself once pressure was released???????

Just thinking out loud.

Did you call a Priest yet?

 

Checked the HPOP, looked good, only light spray back there.
There are two metal lines that have rubber grommets at the block, they looked good too.
No oil in turbo, inside the pipes clean.
Priest ran away screaming.

 

I guess the only thing you can do now, is to watch it close.

Strange.

 

That sure is a real headscratcher there
be real interested in how this story ends

 

Did another 400 miles, level still good.
Had a scare again, saw oil on the tailgate.
I went through a little rain and I guess the chassis got wet and road spray got mixed in and deposited on the rear.
Still can't find where it could have come from.

On a side note, I looked at a 2011 250 Lariat diesel yesterday.
I think I'll wait for the 2012 models to show up so I can get a better price.

But not to sidetrack my own thread, I'll keep watching and checking under the hood.

 

Do you have a CCV mod? If so, where is it dumping out?

I know that is a total stretch, and I can't imagine that amount of oil from that, but the one thing I have come to learn is once these engines are wet, tracking down the actual source of a leak is a major pain in the rear. Although on yours, that amount of puking should be noticeable if you can catch it in the act.

I am a little confused on the oily coating of the cab and bed. My first thought is that it is from the exhaust plumes you mentioned, but that is a crap load of oil to run through the engine.

Good luck and keep us posted...

 

I vote for this one, had almost the same thing happen except I knew my o-ring was leaking.
I didn't think it was that bad and ran a bunch of errands, I got back to the driveway and the truck died HPOP was out of oil.

I have had an oil leak on HPOP o-rings (for the lines going to the heads) twice but never had it seal back up mine were shot. Maybe one of yours are loose and it sealed up. Before you dive into it I would pick up the Mechanics Parts Cabinet" Combo kit. from Clay. It contains most of the o-rings you will ever need to keep your 7.3 running.

Good luck

 

Consol, yes, I did the mod.
It dumps at the left front wheel well.
The cloud was at the read, couldn't catch it in the act.
The oily film on the tailgate and cap rear window was evidently from oil vaporizing and blowing back.
The low pressure area behind pretty much all vehicles pulled it back onto the rear.

The bulk of the oil "appeared" to originate just behind the alternator.
At least thats where the majority was, and in the valley.
The HPOP area did have some spray.
The connections at the HPOP are clean, no evidence of oil.
They are tight, checked that when it happened.
Dang thing was HOT back there!

Did another 200 miles yesterday, no issues.
If I could only be looking at the engine when it puked....

 

Lost two quarts night before last on a 90 minute drive.
Oil is in the engine valley and sprayed on the tailgate.
Cleaned everything up again and still can't find a leak.

Other than the HPOP, what on the top of the engine near the alternator has oil going through it?
The dog house area is clean....

 

Your HPO rail has a plug at both ends.

 

I found the leak finally!!
It is located right behind the alternator and down on the engine facing the driver side.
It is a metal tube inside the black plastic guard tubing.
The line is about 8" long and the other end goes to the top side (driver) near the valve covers. There is a gray/silver nut about 5/8" that attaches both ends. It appears to be some type of press on fitting on top of it and it wiggles enough to allow oil out. It is leaking right where the arrow is pointing.
Recommendations?

 

Dieselorings.com
Replacement O-rings for Ford Diesel Engines

 

Here's some info about the HPOP outlet fittings and HPO lines. You can purchase the disconnect tool
at the link posted by Richard.

 

Great!
Thanks y'all!
I just ordered the o-ring kit.
Anyone know the width of the opening on the tool?