Two weeks ago we had a cold snap that threw a low fuel pressure warning along with a reduced power code on my truck. Definitely froze the fuel because it ran very poorly and died. Got it thawed, cycled my ignition like 40 damn times until it stopped sounding round pumping (jumpered to my wife's gasser), good fuel put in there and Opti-Lube Winter formula (demulsifier) and changed the filters. No metal shavings in the filters, but the rail mounted bowl definitely had some clear liquid in there when I first opened it, so water?

It hit -33°F with wind chill last night and on my drive to the office this morning (-8°F) it threw a low pressure warning, then it went into reduced power. I got to my office, shut it down, then restarted it and the warnings were gone, but the CEL remained because of the reduced power deal. The truck cooled down and I just went out to move it from the east side of my building to the west side (to keep it in the sun, it's 14°F out there now) and it threw a low fuel pressure warning.

These two cold snaps have been really rough on the truck and from what the dealership diesel master tech told me, Colorado gets crap diesel fuel. I've religiously changed my fuel filters every 15k miles or sooner, each time using Ford filters, zero issues changing filters. I think my fuel pump sounds loud this winter. I have a diagnostics appointment scheduled next Thursday which is the quickest Ford could get me in.

Anyone else gone through this? What was your culprit? Is that Opti-Lube Winter demulsifier pretty good? I thought it was supposed to cover the fuel to -35°F or so.

 

Yes, the OptiLube is good stuff. Power Service Diesel 911 is good for after your fuel gelled. You should carry a bottle for emergencies.

I'd seriously give some thought to changing to another fuel station. Around here (NE Wisconsin) the station better label the fuel pump if the fuel IS NOT winterized.

 

Good to know about Opti-Lube.

I did switch stations and they all say winterized fuel. I’m getting it towed to the dealership. Low Power Mode because of Low Fuel Pressure and it was getting jerky when depressing the accelerator. Fuel pump is loud, whining and gritty sounding when cycling the key to prime for a start. IDK.

 

Not to over simplify but (as stated above) shop around and get the best grade of fuel possible during the winter.
Are you plugged into the block heater ?

 

Yep, plugged in all night. As far as I know, the block heater just heats the coolant.

 

You are correct.
Fuel in the tank will be at "ambient temperature". The fuel in the tank will warm up as the engine warms up and the fuel that is not needed by the engine is returned to the tank.
I have witnessed diesel equipment (trucks, fork lifts, generators, etc) that had to be relocated to a heated warehouse and "thaw out" for 24 hours before it would start. At that point it was just left running until the weather warmed. I have a John Deere diesel tractor that does not have glow plugs. Should I let it sit out in zero degrees temperature, I have to enclose the engine compartment with a blue tarp and put a propane torpedo heater blowing warm air under the tarp to get tank and engine warm before it will start.
I am in Montana. Anti-Gel Cold Weather Diesel Treatment is the norm here during the winter.

https://lucasoil.com/products/fuel-t...esel-treatment

 

The tow truck driver said the fuel pump or line was buzzing loud in the cab. I heard it as well. The dealership just called. No ETA on when they’ll be able to look at it. More than likely next week.

My loaner is a 2012 F350 6.7 with a tuner and the thing is pushing like 1,200hp or so. Zero emissions crap on it. I guess it didn’t have a hard time starting in the cold. Registered in Michigan. Haha.

 

Dealer just called and said I gelled. Weird how I had the same thing happen before with zero evidence of gelling in the filters, but ok. They can’t proceed with any further diagnostics before addressing the filters and they said my lower fuel filter housing needs to be replaced, without reason. I’m waiting on a call back after the service manager speaks with the diesel master tech.

 

Emissions crap has nothing to do with fuel gelling. If it didn't gel up, the fuel has something in it preventing it from gelling. Nothing different on a truck with emissions or without emissions between the fuel tank and then engine.

 

Dealership never called back. The estimate they sent me for replacing the filters and lower filter housing was $426 plus $275 in diagnostics. After I talked to the service guy and told him I could change my oil and filters while drinking beer in my gravel driveway in 90 minutes, he said that the estimate was way too high. Not really sure what's going on. Hurry up and wait I guess.

 

Well........ Hmmmmm
They had it long enough for the fuel to warm up and got it started...... But IDK
Seems the newer model truck it is the more we hear of these "issues"....
Lot's of new owner's who never owned a diesel and lack knowledge about the additives during the winter. Some park in a heated garage and get stranded when they park it at the airport for a few days while they travel for business.
You may be better off just going for a "face to face" conversation and look at your truck while it is there...

JMHO

 

I'm aware of the additives, but will admit I had no idea about emulsifier VS demulsifier.

Coincidentally, the dealership just called. The lower filter housing is cracked, so it's sucking air. I suppose that explains the buzzing noise. They lowered their price by $200. Yay.

I still don't understand why I gelled with Opti-Lube Winter in it. I confirmed where I bought fuel, nobody has issues with their winter diesel, so I have a real hard time believing it was water in the fuel. Literally everyone I ask has had zero gelling issues buying fuel where I last fueled up.

My '86 6.9L IDI and '00 7.3L never had these issues. It never mattered how cold it got. Never. It's that crap rail mounted fuel filter setup, at least that's what the dealership blames. The guy got pretty animated on the phone ranting about the rail mounted fuel filter system.

I will have a heated shop constructed by the end of the summer.

 

Hind sight is always 20 / 20.... I have been there many times.

Cracked housing.... ??? .... Depending on a lot of different things.. I'd clean it off, spray with some starting fluid and slather a layer of JB Weld over the crack... but, that's just me.

Be sure to tell them you want all of the parts they replace. That mechanic will JB it and sell it to someone who knows nothing about mechanics.

I know you are ready to get your truck back. Strange things happen when left at shops very long.

 

JB weld the plastic housing? Would that work?

 

JB has gotten many a piece of logging equipment and Baja race vehicles back to the shop.
https://www.jbweld.com/product/plasticweld-syringe