OK just a short follow up. No issues! Low pressure oil pressure still maintains in range unchanged from post repair. High pressure is normal as well. I am glad I went the threaded plug method. Thanks to everyone who contributed to this thread.

 

Thanks for the update. I still wonder about this. Could it be that a lot of the ball failures are just the damn ball popping out only because they were not staked correctly or tolerances were off.

 

Glad to hear back it's still going. Thanks for the update.

 

OK, one last update. HPOP failed! I began to notice a lack of power when accelerating. After some time trying to convince myself I was imagining something that wasn’t there, I watched the icp. After hitting about 2300 psi the pressure would drop to around 900 psi until I let off the accelerator. The ipr was at 85 during this low pressure period. Did the ipr fitting air test and heard oil bubbling. Removed pump cover and removed pump. Found that the pump had about 1/8” end play. Checked for seal leak by plugging the discharge hole any applying air to suction. Saw this test in a YouTube video. Air and oil came out the shaft seal. Replaced the pump with a unit from Pensacola Diesel and all is back to normal.
The thing runs great, at least for now. But we all know how this story goes. What’s next?
Thanks again to everyone who helped and followed along on this adventure over the last 2 plus years.

 

I hope your new HPOP lasts, but Pensacola does not have the best of reputations. I hate to even post it, but it is something for future "viewers" to consider:

https://www.bbb.org/us/fl/pensacola/...-0683-16003170

https://www.thedieselstop.com/thread....227927/page-2

That said, at least they do sell one with a billet housing (one of the common issues with the original HPOPs)

 

I appreciate the info bismic. These guys are local to me and have been straight up with me. They offer OEM parts in the original package as well as aftermarket. Since I can look them in the eye I feel pretty good. I will however post any negative experiences when and if they occur.
Again, I do appreciate your input.

 

So after 2 years, it failed. I don't know how to read into this. Was that the BB was blew out due to internal leakage from high to low, causing the high pressure pump to overwork when you put in the NPT screw or it's simply Ford's quick method like so many oring failures on the 6.0l of plugging a hole it needs when they bore the hole for something else.

If it's me, I would open the the pump up, just to see what's going on. Is there a video of someone doing that to find out what causes the 6.0l pumps to fail? I think dirty oil probably cause some of that because the tore off IPR screen sending debris into the pump, but that's the obvious path. I wonder if there are other things in there, such as broken over pressure spring (is there such a thing in there?), etc.

I really enjoyed reading this thread, especially I am dealing with my truck on low pressure issue also. I haven't gotten time going back to it, but I will try.

 

I agree that some HPOP issues may be related to debris or contamination. That said, if the IPR screen is torn, the trash has already gone through the HPOP. The IPR operates as a dump valve for the high pressure oil. Anything going through the IPR screen gets dumped back to the crankcase.