Notices
6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Repeat Injector O Ring Failure Please Help!

Thread Tools
 
Search this Thread
 
Old Nov 7, 2024 | 02:37 PM
  #1  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Repeat Injector O Ring Failure Please Help!

hello, I have been trying to get my 6.0 running for about a month now and I have come to the last remaining issue on this truck. This is the second time it has happened now and I just would like to hear y’all thoughts on a solution for this.

Attached is a picture of the injector on the same cylinder that it blew the first time. and it seems like all of the injectors look burnt on the bottom as shown in the second attached picture. I have a feeling that the crush washers aren’t working even though I am torquing down to spec (26ft lbs) and cleaning out the holes for hold down and the cups.





What could be causing this to happen?
 
Reply
Old Nov 7, 2024 | 03:00 PM
  #2  
Hartwig's Avatar
Hartwig
Cargo Master
Photogenic
Shutterbug
Loved
Top Answer: 1
Joined: Oct 2018
Posts: 2,811
Likes: 1,911
From: unfortunately Germany
Club FTE Gold Member
A bad injector sleeve in the head. Please post a picture of injector seat in the head.
This is what it not should look like


 
Reply
Old Nov 7, 2024 | 05:38 PM
  #3  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by Hartwig
A bad injector sleeve in the head. Please post a picture of injector seat in the head.
This is what it not should look like





These are a couple i took earlier trying to get a better look for myself
It seems odd that a new machined heads and rebuilt motor would have this issue not even 100 miles into being put in.
 
Reply
Old Nov 7, 2024 | 06:12 PM
  #4  
vacuumbed's Avatar
vacuumbed
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
fosp,
Where did the heads come from?
 
Reply
Old Nov 7, 2024 | 07:58 PM
  #5  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by vacuumbed
fosp,
Where did the heads come from?
They came off an old thomas built school bus with 60k miles on it. Engine was refreshed and bulletproofed, heads were machined.
 
Reply
Old Nov 7, 2024 | 09:12 PM
  #6  
vacuumbed's Avatar
vacuumbed
Tuned
15 Year Member
Liked
Loved
Community Favorite
Joined: Apr 2007
Posts: 322
Likes: 42
From: Herriman, UT
I wonder if the machine shop missed something. I'm sure other members with more experience than me will chime in.
 
Reply
Old Nov 7, 2024 | 11:08 PM
  #7  
Hartwig's Avatar
Hartwig
Cargo Master
Photogenic
Shutterbug
Loved
Top Answer: 1
Joined: Oct 2018
Posts: 2,811
Likes: 1,911
From: unfortunately Germany
Club FTE Gold Member
Clean these sleeve so that you can see the sealing surface. I suspect this is the problem



 
Reply
Old Nov 8, 2024 | 07:02 AM
  #8  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by Hartwig
Clean these sleeve so that you can see the sealing surface. I suspect this is the problem


You think I need to replace the cups in the head? Or just need to be cleaned
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

 Verdad Gallardo
story-1

Top 10 Fords at 2026 Carlisle Ford Nationals

 Joe Kucinski
story-2

3 Best / 3 Worst Parts of Modern Ford Ownership

 Brett Foote
story-3

10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

 Pouria Savadkouei
story-4

Every 2026 Ford Engine Explained

 Brett Foote
story-5

10 Ugly Ford Trucks That We Still Kinda Love

 Joe Kucinski
story-6

10 Things Every Truck Owner NEEDS (2026 Edition)

 Michael S. Palmer
story-7

Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

 Verdad Gallardo
story-8

Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

 Joe Kucinski
story-9

2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

 Brett Foote
Old Nov 8, 2024 | 08:01 AM
  #9  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,834
Likes: 3,121
From: Jersey Shore
He’s asking to clean the injector cup so we can see the extent of the damage. If an injector was loose when installed, in 100 miles the cup certainly could be burned to the point of not being usable.
 
Reply
Old Nov 8, 2024 | 09:13 AM
  #10  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by TooManyToys.
He’s asking to clean the injector cup so we can see the extent of the damage. If an injector was loose when installed, in 100 miles the cup certainly could be burned to the point of not being usable.
Sounds good, will update yall once I get back to the shop monday and will send new pics of each cup cleaned out. Thanks!
 
Reply
Old Nov 12, 2024 | 04:32 PM
  #11  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by Hartwig
Clean these sleeve so that you can see the sealing surface. I suspect this is the problem




These are the same 2 after i cleaned them up, these pictures are the best I can take.
 
Reply
Old Nov 13, 2024 | 12:47 AM
  #12  
Hartwig's Avatar
Hartwig
Cargo Master
Photogenic
Shutterbug
Loved
Top Answer: 1
Joined: Oct 2018
Posts: 2,811
Likes: 1,911
From: unfortunately Germany
Club FTE Gold Member
The first sealing surface appears to be damaged at one point (red circle). The second sealing surface is unusable. Both are caused by improper injector assembly.

I would not replace the sleeves with the head installed.




 
Reply
Old Nov 13, 2024 | 07:28 AM
  #13  
fosp's Avatar
fosp
Thread Starter
|
Cross-Country
Joined: Oct 2024
Posts: 54
Likes: 13
Originally Posted by Hartwig
The first sealing surface appears to be damaged at one point (red circle). The second sealing surface is unusable. Both are caused by improper injector assembly.

I would not replace the sleeves with the head installed.


is there a big issue with installing them in the truck? I have done it on 7.3s with no issue but it would just save a lot of time in my end since it’s with the cab on
 
Reply
Old Nov 13, 2024 | 07:31 AM
  #14  
bismic's Avatar
bismic
Fleet Owner
Community Builder
Liked
Loved
Community Favorite
Joined: Nov 2003
Posts: 27,920
Likes: 3,637
Club FTE Gold Member
I'm curious - are these re-manufactured injectors that you just acquired or that you just re-built?
 
Reply
Old Nov 13, 2024 | 07:56 AM
  #15  
TooManyToys.'s Avatar
TooManyToys.
Hotshot
Photogenic
Photoriffic
Shutterbug
Joined: Dec 2014
Posts: 17,834
Likes: 3,121
From: Jersey Shore
Here are the sleeve replacement instructions from the International VT-365 service manual.

[img alt="

"]https://cimg3.ibsrv.net/gimg/www.ford-trucks.com-vbulletin/1540x2000/screenshot_2024_11_13_at_8_51_54_am_dd1cda99a2b7ac 18cb1274b28d097b5790de7504.png[/img]

[img alt="

"]https://cimg4.ibsrv.net/gimg/www.ford-trucks.com-vbulletin/1600x2000/screenshot_2024_11_13_at_8_52_05_am_c76aea8bd6f666 1f3ae474e9d9f9bc34e281f565.png[/img]

[img alt="

"]https://cimg5.ibsrv.net/gimg/www.ford-trucks.com-vbulletin/1540x2000/screenshot_2024_11_13_at_8_52_48_am_90da21b7b5daef 8474b40a33211f4e4e343099c2.png[/img]

 
Reply



All times are GMT -5. The time now is 09:36 AM.

story-0
This Hennessey Takes the Expedition Tremor's Off-Roading Capability to the Next Level

Slideshow: The VelociRaptor Expedition gains a lift, upgraded suspension, Brembo brakes, and trail-ready equipment while retaining the stock 440-horsepower EcoBoost V6.

By Verdad Gallardo | 2026-06-12 11:01:55


VIEW MORE
story-1
Top 10 Fords at 2026 Carlisle Ford Nationals

Slideshow: Top 10 Fords at 2026 Ford Nationals

By Joe Kucinski | 2026-06-09 11:10:08


VIEW MORE
story-2
3 Best / 3 Worst Parts of Modern Ford Ownership

Based on years of owning multiple modern Ford products.

By Brett Foote | 2026-06-09 10:53:36


VIEW MORE
story-3
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches

SPONSORED: From muddy boots to rain-soaked cargo, these upgrades address some of the most common frustrations Ford truck owners face every day.

By Pouria Savadkouei | 2026-06-08 18:50:34


VIEW MORE
story-4
Every 2026 Ford Engine Explained

Here's everything you need to know about every Ford engine available for the 2026 model year.

By Brett Foote | 2026-06-05 12:58:01


VIEW MORE
story-5
10 Ugly Ford Trucks That We Still Kinda Love

Slideshow: 10 ugly Ford trucks that we still kinda love.

By Joe Kucinski | 2026-06-03 09:51:16


VIEW MORE
story-6
10 Things Every Truck Owner NEEDS (2026 Edition)

Slideshow: the best gifts for dads & grads

By Michael S. Palmer | 2026-06-03 15:43:58


VIEW MORE
story-7
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath

Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.

By Verdad Gallardo | 2026-06-03 11:38:36


VIEW MORE
story-8
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer

Slideshow: 10 most expensive Ford trucks ever sold on Bring a Trailer.

By Joe Kucinski | 2026-05-27 16:24:34


VIEW MORE
story-9
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)

Here's everything that has changed for the latest model year.

By Brett Foote | 2026-05-27 16:17:28


VIEW MORE