late HPOP test device build
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Cargo Master
Joined: Oct 2018
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From: unfortunately Germany
late HPOP test device build
Hello Gentlemen,
I would like to build a device to test second/late generation HPOPs.
To see how they work I have started to disassemble a pump.
Can anyone tell me how these inserts are fixed in the housing? I can't hammer them in, nor can I pull them out with an impact hammer.
I would like to build a device to test second/late generation HPOPs.
To see how they work I have started to disassemble a pump.
Can anyone tell me how these inserts are fixed in the housing? I can't hammer them in, nor can I pull them out with an impact hammer.
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Cargo Master
Joined: Oct 2018
Posts: 2,811
Likes: 1,908
From: unfortunately Germany
also here the pictures if someone is interested.
The inside of the pump is very simple. In principle, nothing is inside that could break down.
If such a pump fails, it can only be caused by one or more of the 4 valves failing, otherwise there is nothing inside that could fail.
I also have an 03 engine and will also disassemble the 03 pump. These have much more common problems as we all know.
The inside of the pump is very simple. In principle, nothing is inside that could break down.
If such a pump fails, it can only be caused by one or more of the 4 valves failing, otherwise there is nothing inside that could fail.
I also have an 03 engine and will also disassemble the 03 pump. These have much more common problems as we all know.
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Cargo Master
Joined: Oct 2018
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Likes: 1,908
From: unfortunately Germany
I will also disassemble the 03 pump to see where problems may occur. It is a mystery to me how the gear could loosen with your pump.
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Cargo Master
Joined: Oct 2018
Posts: 2,811
Likes: 1,908
From: unfortunately Germany
In the early HPOP there are 7 pump elements, the late pump has only 4 pump elements, but these are larger.
In general, the early pump has a much more complex design than the late pump. But why the early pumps fail so often I could not see. The functional principle is a million times in all kinds of pumps in use .
In general, the early pump has a much more complex design than the late pump. But why the early pumps fail so often I could not see. The functional principle is a million times in all kinds of pumps in use .
Fleet Owner
Joined: Nov 2003
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"Stuff" I have accumulated .........................
Credit to FordDoctor, CNCFab, DieselSite (hopefully they do not mind that links to their information is copied and pasted.
Failure mechanism in the 03-04 HPOP's - and possible "fix":
https://bbs.homeshopmachinist.net/fo...ed#post1008858
https://bbs.homeshopmachinist.net/fo...iesel-hpop-fix
Failure areas:
https://cncfab.us/i-30498072-cnc-fab...hpop-stg1.html
https://www.dieselsite.com/2003-2004...lpumphpop.aspx
https://www.forddoctorsdts.com/galle...50-60l-hpop-1/
https://www.forddoctorsdts.com/galle...51-60l-hpop-2/
https://www.forddoctorsdts.com/galle...-hpop-failure/
https://en.wikipedia.org/wiki/Ford_Power_Stroke_engine
03-04.5 HPOP issues include a housing weakness (back plate wear-out) and swash plate issues (a light press fit is intended to hold the swash plate in place but apparently they can spin and cause failure). Also, there is documentation on rotating cylinder cracking. Wikipedia states that the gears were weak and cracked.
Credit to FordDoctor, CNCFab, DieselSite (hopefully they do not mind that links to their information is copied and pasted.
Failure mechanism in the 03-04 HPOP's - and possible "fix":
https://bbs.homeshopmachinist.net/fo...ed#post1008858
https://bbs.homeshopmachinist.net/fo...iesel-hpop-fix
Failure areas:
https://cncfab.us/i-30498072-cnc-fab...hpop-stg1.html
https://www.dieselsite.com/2003-2004...lpumphpop.aspx
https://www.forddoctorsdts.com/galle...50-60l-hpop-1/
https://www.forddoctorsdts.com/galle...51-60l-hpop-2/
https://www.forddoctorsdts.com/galle...-hpop-failure/
https://en.wikipedia.org/wiki/Ford_Power_Stroke_engine
03-04.5 HPOP issues include a housing weakness (back plate wear-out) and swash plate issues (a light press fit is intended to hold the swash plate in place but apparently they can spin and cause failure). Also, there is documentation on rotating cylinder cracking. Wikipedia states that the gears were weak and cracked.
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Cargo Master
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Cargo Master
Joined: Oct 2018
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From: unfortunately Germany
Since yesterday I am on vacation
https://www.ford-trucks.com/forums/1...s-on-6-0s.html
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Cargo Master
Joined: Oct 2018
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From: unfortunately Germany
Since the new pumps run more reliably, I think that would be a reasonable change in a rebuild.
Maybe we could create a kind of list in which the changes are listed? The ICP harness could be extended.
Maybe we could create a kind of list in which the changes are listed? The ICP harness could be extended.
Lead Driver
Joined: Mar 2010
Posts: 5,505
Likes: 256
From: Woodbridge, Ontario, CA
If the engine is from a late build 2004 model year, the branch tube would need to be replaced with one from a 2005 and later engine. This would not be doable for a 2003 or early build 2004 engine with the straight oil rails that have standpipes which thread into the 2003 specific branch tube.
Hotshot
Joined: Dec 2014
Posts: 17,829
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From: Jersey Shore
You're saying the early blocks are different so where the branch tubes can not be swapped?
My understanding is it can be done with changing the rocker carrier on the heads, oil rails, branch tubes, right valve cover, stand pipes, HPOP, STC fitting, and HPOP cover. The ICP harness would need to be lengthen to reach the valve cover.
My understanding is it can be done with changing the rocker carrier on the heads, oil rails, branch tubes, right valve cover, stand pipes, HPOP, STC fitting, and HPOP cover. The ICP harness would need to be lengthen to reach the valve cover.