So after much research here and elsewhere I dove into the injector orings. I was using quarts of oil/100 miles approx. Talked with a good friend that is a diesel mechanic and he concurred. Ordered orings, oil galley orings and oring lube from dieselorings.com. Printed off instructions from swamps diesel. Pretty straight forward, no problems in removing injectors, popped right out. Spent lots of time vacuuming cylinders with hand vacuum pump, worked pretty good, next time will buy a air powered vacuum pump. Did find it helpful to run a piece of wire thru tubing to straighten it out so it would get through the hole, especially the back holes, I then pulled the wire out and hooked up vacuum. Checked GP's while there and found one bad, just replaced 40k ago along with harness/gasket. Put in a new set of Motorcraft, did not change harness/gasket. Long story short, all back together, again following swamps instructions, fired right up. Ran a little rough during test drive but got a little better to a point. Had a definite miss in it. Drove 50 miles and still had rough idle and a miss at mid throttle, more research and a call to mechanic and he assured me was just air still working thru system. Let sit over night and went for another drive, still rough idle and miss at mid throttle, now I am thinking I missed something or have a broken wire in harness, since I did not change them. Pulled off driver side cover, inspected wiring, rechecked injector plugs and clips and noticed that #8 seemed to go on a little easy, to easy. Upon further inspection found that the orange? wire had come loose in the male plug but still inside plug. Removed gasket and able to bend very small tang up and slide back into plug, back on truck, all hooked up and presto, runs like a champ. Moral of the story, probably should have replaced the harness/gasket but it looked so good, just give them a good look and inspect those 2 wires that go into the male injector plug, if you look at the end you should see both silver terminal connectors snug in the plug. Thanks to all those who posted their thoughts and instructions for me to read. After 200 miles, down 2 qts, not sure if I messed up a oring during install or not? Will tear back into it Wednesday.

 

That's a little unusual. I'll summarize:

Hey guys. I did my part and actually searched the forum for a solution to my problem. I applied what I learned from the search and except for a hiccup in procedure - all is well. Thanks for making this easy when I hit the SEARCH button. Carry on.

Congratulations on many levels!

That being said... that hiccup in procedure:

1. The UVCH link in my signature is very helpful with issues like this.
2. I always run the engine with the vlave covers off until it reaches full temp. This allows much of the air to clear from the rails and I can watch #1 and #2 start to spit oil when it does. It also allows me to hot-torque the injector bolts before buttoning up.

I'm not saying you need to go back in, but if there is a sharp increase in knock under the hood over the next 500 miles and you feel the urge to pop the covers again - keep the hot-torque method in mind. This would be neither common nor unusual - it just happens from time to time.

 

Thanks for the info, I will keep a close watch on it.