Hopefully someone here can help.
Bought an 07 a year ago. Thought the deal was too good, turns out, it was. HPO leak, blown head gaskets and bad U joint. Few thousand dollars later, I believed I had the truck I always wanted. Short of a few hiccups, batteries, alternator, EBS sensor.
The truck has 178k. Egr deleted, New motocraft head gaskets with studs, sinister coolant filtration and Livewire TS programmer.
A few weeks ago, rolling down the interstate, cruise control set, truck started bucking and missing. Turned off cruise and reduced speed. Didn't do it again til nex day. Got worse and worse til truck shut off while heading to work. Would not restart until it cooled off. I thought it to be another HPO leak. Let it sit for three hrs or so, would crank and run fine till I warmed up.
While going over it, Checked the screen on the Ipr, I couldn't make out where the level was on the dipstick. I dumped the oil and found 35qts in it!! That's right 35. Took it to my mechanic friend to get his advice. He thought injector seal. He used tracer in secondary fuel filter and found one leaking. He pulled all 8 and replaced all orings and one injector. Got it back and sure enough, still getting feul in crank case. I drained it last night, cycled the switch 3 times till the fuel pump shut off and there's a stream of fuel coming outta the oil pan. Not a drip. A stream!
Ready to light a match to it!!
Got a scan gauge 2 today. Gonna get some numbers and plug off fuel line to heads, one at a time to find which side is leaking. Could this be a cracked head somehow? Cracked through the fuel galley? Maybe he didn't replace all the injector orings? If injector leaks, it leaks into the cylinder and hydro locks? I did drain some coolant to remove degas bottle and it is a funny color. Nose doesn't work so well all the time and can't tell if its in there or not. A test for that?
If anyone has experienced this before , your advice would be most appreciated. Thanks!

 

Bad crush washer on injector or cracked head. Those are my guesses.

 

Could be a cracked injector body also. Isolate which is leaking and reinstall fuel system. Pull valve cover and turn on the fuel pump to find the injector. Pull and inspect said injector, if the orings are intact, get a new one.

 

I would pull the valve cover after your test to locate the side its on and see where its coming frome im thinking it could be and injector internal o-ring. There is an oring in the injector under the fuel body nut if that leaks it could do the same thing did you heads get pressure tested when the studs were done. Im going to bet that your leak is on the same side as the one that had the bad injector unless your mechanic switched there holes and i would also bet you leaking injector is next to the one that failed which starved the other injectors. Which injector failed 7 or 8 just a guess

 

Thanks for all the input guys. Tearing into it today. Will post my findings later.

 

bad injector or injectors. got to pull each one and pressure test it. Happened to me. I had an 04 6.0. That was the last straw for me. Traded it in on a 6.2 new gasser. couldn't be happier.

 

Love this truck but I'm with u....already looking for another.
Thanks for your input.

 

Did you find your leak ?

 

No sir. Not yet. Appears as though I'm getting the same amount of fuel dripping from the pan on both sides. Nothing visible or audible from topside of injectors. Now way I've got two bad heads! I've babied it since it was done. Slight mishap one time with sinister coolant filter hose popping off and loss of coolant caused overheat. Gonna pull all injectors and have them bench tested!?!

 

Pulled all 8 injectors, had bench tested. 4 bad, bit the bullet, bought all, new, OEM injectors. Thought about Casserly. Any input?
Full batteries(had cheap *** charger hooked up to tend while first attempt to crank after install)[probably a bad idea](h/s is always 20/20)
Key on/engine off. I heard a pop! "Almost like a chewing gum bubble, like roughly a 4" bubble, deeper sounding". Injector clatter was good, so I turned it over anyway.
PCM fault on dash. SCT Livewire tunner, set at 75HP tow tune showed...
All 8 injectors-circuit low.
Hooked up Scan gauge, key on, engine off, ficm voltage slowly climbed from 42 to 48V well after glow plug light went out(30 seconds). Not right?
Tried again.
ICP at 7 psi and 84.5%IPR duty. No code but no start!
Ficm maintains 48v while cranking.
2 problems, hpol and ficm?
Maybe harness and ficm?

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Did you smell any ozone after the pop? Like a burnt circuit or something electrical?
Usually just injector codes low is a FICM from what I am told.

 

Im assuming the leak was resolved when the injectors were changed ? How long have you turned it over scense the install and did you prime the oil system (hp oil rails) before the valve covers were put on, also did dummy plugs and stand pipes look good.

 

I'm not going to address the pop but with all of the head swaps that these things have had on them, if the injector clamps are the wrong style for the head casting, a lot of times the injectors won't seat properly even though they are torqued to the correct specs.

 

another source of the pop could be if you used any kind of flammable cleaners down the injector bore, break clean ect, and any was left in the cyl when you turned on the key it could have ignited from the glow plugs. as far as all 8 injector low codes look over the harness really close and ficm plugs. could be a plug not seated all the way