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Recently got DEF injector fault, tested and proven bad; exceeds 11-14ohm range from research. Tried two dealerships, talked to techs, and even Ford parts division directly. New injector housings shipped to dealers and other parts stores are manufactured differently and will not work. Online parts catalog images show the part as it should be, but always receiving the wrong version. Original injector housing has straight collar but new one has a lip. I have had trouble finding the injector itself (Ford seems to not consider this an option). One parts specialist stated they keep these on hand because the technicians keep breaking the plastic feed nozzle. Technicians at one location stated they'd never seen my version while at another, they'd never seen the new.
Parts tech called me back and stated it WAS a manufacturer error, stock was supposed to be recalled, but no information on when correct part will be in supply system to issue. Ford still has no response.
Simple solution until supply is fixed, seems to be just swap injectors. The new injector assembly ranges from $150-$350 depending on the shop; aftermarket versus OEM as well. After researching various sites, an injector (Dorman 904-504 fits 2011-2016 F250-F350) is/was available: shady sites also have versions. Summit Racing Equipment $120 expected deliver date was 30 days so figured this was waste of time. Auto Zone $205 but unavailable for order.
Troubleshooting is not easy while installed, unless you "modify" some test leads to fit between the injector module and the underside of the cab, or have an old wiring harness to plug in.
Removal from the truck is easy; disconnect electrical lead, remove fluid line, 2 x 13mm nuts.
Disassembling the faulty injector from its housing was relatively easy; remove feed line retainer clip, remove injector retainer, gently press/pull assembly out of housing. Attached images for reference: original injector assembly, replacement that Ford certifies fits, original injector disassembled.
Part number off bad injector pulls up in Ford and gets changed.
Original injector #: AL3E-5J281-AB
changed in system to: AL3Z-5J281-A
Replaced by: AL3Z-5J281-B Original Original: collar straight Original: collar straight New New: collar has lip New: collar has lip
Last edited by AJJr; Nov 23, 2022 at 07:11 PM.
Reason: Updated information
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