Well... my jug is high on crack. I've done the obligatory search and I discovered this is a "hot" topic after a decade of degradation. I guess plastic parts should be prohibited from being paired with Powerstrokes. I've done a quick search for the bottle and I found this unit in the image below for 70 bucks, but I want to know if anybody has found a better one (or cheaper with OEM quality as a minimum).

 

I guess I'm one of the "unlucky" ones who've had to replace my bottle multiple times for cracks in the same area. I've the replaced the original plus 2. The second Ford replacement is showing signs of stress in the same area, too. It seems to be lasting the longest of the 3. I can see it get larger over time, but has not "opened up" yet. I have seriously thinking of fabbing an aluminum tank with a sight glass to replace it when it fails again. I have found no aftermarket units to replace them. There are some for other Ford models, but don't seem to exist for the Superduties.

 

In October I replaced mine with an OEM from Tousley Ford for $59.87

 

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these guys make fuel cells and over flow tanks all day long... and for a great price i bet they could even make a factory looking one for us

 

Hmmm.... I have a local fabricator that I have a great working relationship with. I've had them make custom stuff for me before and they ended up reproducing them for other customers. They like when I bring them something new and they go real easy on the price for me.

In researching this, the problem starts with the ability to see the fluid level. A sight glass/plastic has to survive temps that exceed boiling water - and shocks from extreme cold to extreme hot in a flash (radiator venting in winter driving). A float with a mechanical or electrical indicator would work better for an installation that would be considered permanent. So... an aluminum degas bottle with a similar shape to the original and identical mounting positions. A screw-top for the vent cap, and a level indicator on the deep side.

 

You could also just look inside or use a wood dowel for a dip stick.

 

Servo gauges, netbook with manuals on PDF, AE, and a stick. Check!

 

Tug, Sometimes simple is good enough.

 

Never replaced one yet... I may replace this one, simply because the last set of injector cups stained it pretty bad.

 

So what do you think is causing it to crack? Seems like there must be something else wrong to me, I've never replaced mine and have spent countless hours with my knee or gut laying on top of it.

 

Exactly what I am thinking...

 

Opening when hot may be a problem with the dipstick method - Sightglass would be nice.

 

Tousley Ford has them for $60. I thought Clay stocked them too, you might shoot him an email and ask for PN 2C3Z 8A080 AA

 

I am wondering the same thing. Something with the mounting or supports must be putting more stress on one area vs another. I've never had to replace that part on any of my personal or fleet trucks.

 

I'm sorry but that just cracks me up. Thanks for helping me crack a smile...it's been one of those days.