I have 2005 6.0 Dually.At 20,357 miles this truck needed to have the fuel pump, #8 injector and EBP sensor replaced. Today at 30,005 miles I picked the truck up again and they replaced fuel pump and #1 injector. This is getting old real fast. Both times I had the truck towed in and waited a week for repairs. My question is shouldn't the tech replace all the injectors? The service advisor says it costs to much and this is a fluke thing. What do you guys think?

 

when the 6.0 was first introduced, there was a lot of injector problems, so much that ford told us as techs to replace all of them. As time and design changes came, so went that thinking. Now we are told to replace only the defective ones. There is an extensive process in the proper diagnostics, unfortunately, not all techs do it. The way the pay scale goes, many techs dont do the right thing, just the fast thing. A very smart thing to do when there is repeat injector failures, is test the fuel pressure. If you dont maintain 45 psi at wot, injector problems are inevitable.

 

I though fuel pressure on the ford diesel trucks were around 2600 psi not 45 psi
???

 

the fuel supply pressure before the injectors will go 45-65 psi. the high pressure engine oil that operates the injectors will go 500-1400 psi. i think you are thinking of the pre-direct injection diesels with the injector pumps

 

I'd be prepared for a few more injectors to go south on you. I had an 04 that started with 4 bad ones passenger side, then 4 more and a fuel pump, then 4 more and another fuel pump. After all that 1 went on the drivers side and I told my dealer wanted new truck. One week later I had an 05 and couldn't be happier. BTW even with all the problems I still loved my o4.

chadjones99 I think fuel pressure is 45 psi; ICP is 1000-6500 psi?

 

the figures of 500-1400 come from the engine has to have 500 psi to start and the ipr will shut off oil pressure shortly after 1400-1500 psi. much more than that, you will start blowing o rings on the high pressure pump, stand pipes.

 

ohi see, thanks

 

Thanks to all for the replys. In 6000 miles I will be out of the full coverage portion of my warranty. I know the motor is covered to 100k but the fuel pump is in the tank. I too like this truck alot but I make my living out of this truck and pull my racecar with it. I have a very strong feeling that this will happen again.

 

Fluke or water. Watch your fuel purchase and keep the HFCM drained, it doesn't take much water to kill an injector. Are you using a fuel conditioner in your truck when you fill up with fuel?

 

I believe that running fuel additives at double strength in every tank helps with cetane boost, cleaner burn due to cetane boost, better lubricity of pumps and injectors and less coking.

The TSB discusses adding cetane booster additves and I also believe that the additves help water to sperate out in the HFCM filter. As well, using Racor filters (with white Aquabloc media) prevents water/moisture from harming the injectors.

Yes, bad fuel is bad fuel and we have no way to test before we fill up each time. But adding a quality, brand name additive (double strength from what all companies have said) really helps. Additives reduce coking, but does not eliminate it... but constant use is key and will clean up some of the deposits.

I now have 68,000 on my 2003 Excursion with all 8 original injectors and have only flashes done to date. I use Powerservice in every tank... and every tank is key for maxiumum lubricity and protection (I called all fuel additive companies a while back and posted in an old thread).

These trucks are so highly tuned and monitored with sensors (for EPA and performance purposes), that bad fuel, bad sensors and certain aftermarket parts really cause havoc with them.... then one problem leads to another.... and then another.

With 68,000 miles since August 2003, I have filled up in a lot of different stations and my filters (mainly HFCM one) have never looked any worse than a few dark specks of dirt and a tiny bit of sediment... but no real clogging, rust, dirt or other stuff to speak of. Cetane levels here in Kansas is just like the national average (40 - 45)... but I add Powerservice to boost cetane to the 45 - 50 level depending on if I am adding the white bottle in winter or the grey bottle the rest of the time.

Not to say a bad wiring harness is shorting out or a bad fuel pump... it does happen. Take to dealer for a quick look.

Good luck,

Jeff

 

the fuel pump is in the hfcm with one of the fuel filters

 

Thanks Vloney, I nearly posted for a clarification as I thought the pump was in the HFCM.

 

vloney, do you know if the fuel pump is included in the 100k warranty? If not what does Ford warranty their repaired/replaced fuel pump for. I am 6000 miles(about 3 months) to go before the warranty is up. Thanks in advance.

 

its my understanding that the pump is not covered, only the motor itself. if the pump is replaced by a ford dealer i think it will be 12/12

 

Read this link...

http://www.forddoctorsdts.com/articl...icle-06-03.php

Great info and good reson to use Racor/Motorcraft/IH fuel filters and now WIX