I have to get the banjo washers replaced in my 96 Ford 7.3.... the parts cost about 3 bucks from Ford, and the tech wants to charge me 500 to do the job... they say they have to take out the turbo to get to the diesel leak.

From what I see, it looks like there's access, but you'd have to be patient...

I'm not mechanically inclined at all, so doing it myself is not an option.

Would love to hear some solutions.

 

You DO NOT have to take the turbo out to replace the washers on the Banjo Bolt. There are several ways it can be done without pulling the turbo. The main thing you need is an 1 1/4" shallow well socket and a swivel head ratchet. You can also do it with an 1 1/4" combination wrench, but the turbo can stay. Tell your mechanic to go pound salt.

 

They aren't going to remove the turbo. Find an independent shop or two and get some quotes. The bolt may just be loose. If in fact thats the problem.

 

More than likely they just wanted you to believe they were going to remove the turbo for what is in fact a 30 minute job. But on the brighter side, you could always give them the benefit of the doubt...maybe they just don't have a clue what they are doing on your diesel truck!

The banjo bolts in these trucks are known to work themselves loose over time, as pjwoolw says, the bolt may just need to be re-tightened.

 

Here is how you will do it if it is a Cali model:
these tools

remove the engine pull bracket and insert like so:

 

I would be willing to bet the pump is leaking not the banjo washers. But yes it can be done without removing the Turbo. Flat rate time is 5 hours labor which includes pulling the turbo per the book.

 

I agree with Tim , I bet its the pump ...

 

Any idea where and how much an aftermarket pump would run me? I may as well get the unit replaced.

 

Yes as adviced above, first check the banjo bolt if its loose, and second Im with Tim and Rick about the pump. And Ian has the solution for the Cali pump.
The pump is around $120 dollars; buy the cheapest you find, IIRC all are made by Carter. Good luck.

 

I forgot to add:
WELCOME TO FTE!!!
Save these links!:
1994.5 - 1997 7.3L Power Stroke Diesel - Ford Truck Enthusiasts Forums
http://pages.prodigy.net/stevebaz/_i...az/index3.html
http://www.thedieselstop.com/faq/949...an/stjmain.htm
http://www.thedieselstop.com/faq/949...ia/siamain.htm
and run your VIN through this link to see what your truck was built with: Comprehensive Chevrolet, Saturn, GMC, Hummer, Cadillac, Buick, Oldsmobile, Pontiac, Geo, Dodge, Plymouth, Jeep, Chrysler, Ford, Lincoln, Mercury, Mazda Truck, Mercedes VIN Decoder

X2 on the pump buying. Get the cheapest one you can. The "Track Auto" and stealership are the same all the way around except for the price. If this is not your daily driver, I would like to encourage you to tackle this project. You have 24/7 tech help right here. Put a day aside for it. We will help get you through! Where do you live?

 

Jose is spot on with his Paso to dollar conversion! About $120 for the pump.

 

HERE is a link to a kit that includes the pump and all the o-rings for the fuel bowl. Might as well change them while you're at it!

 

Good thinking! and highly recomended!

 

Those links don't work properly, lets try these:
https://www.ford-trucks.com/forums/forum170/
http://www.thedieselstop.com/faq/949...ia/siamain.htm
http://www.thedieselstop.com/faq/949...an/stjmain.htm
http://www.compnine.com/vid.php

there we go