Love my 6.0, and it was great for the first 38,000 miles. Then, 5 months ago two injectors went. These are the C94 injectors used in early-build 2003 (which were redesigned in the first 6 months). Replaced these two.

Last week I hooked up my 5th wheel and headed off on vacation. Injector died on first day. Another died on 3rd day. Another died on 7th day. Vacation cut short. Each time I had to have two tow trucks (tow the 5er to a campground and the truck to a dealer), pay for lodging and car rental while waiting for the repair (over the weekend the last time) and pay the $100 deductable. But that is not the issue.

So that leaves me with 3 of the old poor-design C94 injectors still in the engine. Since 5 have failed in the last 5 months, it is likely that the remaining 3 will fail the next 3 times I tow with this truck, probably leaving me stranded again. Wife refuses to use the truck until its reliability is restorred. Ford refuses to replace the remaining 3 injectors, because they are still "good".

Anyone know of a contact or had any luck getting Ford to make good on this problem and relace the last 3 injectors?

 

Hopefully one of our 6.0 techs will get to this.

My questions are...If you have (5) C-94s and (3) C-95s, do they work the same? Do they fuel at the same rate? Does the computer go nuts trying to figure out the disparity, if the is one? Can the (3) C-94s have a negative impact on the new C-95s?

The injector issue is one that, IMO, Ford has dropped the ball on. While many had no issues with the C-94 injector, it is a known problem. Why not keep the customer happy and just replace the remaining (3)...in this case?

 

Have you tried different dealers? Some are more inclined to work with you.

 

Trust me, the techs know about the problem with the remaining injectors, they would be more than happy to change them. The problem is past what the customer sees. Whenever you do warranty work, you have to clock on your time at start,and clock off at finish. You have to write a story detailing your diagnosis-repair-and verification of the fix. The old parts get sent back to ford, they inspect them, and see if the repair was correct. Any parts that were not defective get sent back to the dealer and charged back for the part.

 

The main moral off the story now is how much warranty do you have left? It sounds like a bad deal on Fords part not to replace them all at once intead off one by one. But Im guessing that GM an Dodge have the same deal. Replace whats defective. But the trouble is these injectors were defective from the start an were changed later on.

 

turbos and egr valves will be next. It was the same way when I worked at a gm place.Make sure they test fuel pressure. Any time you get repeat injector failures, fuel pressure may very well be the cause. You need 45 psi minimum under load. You cant test accurately in the bay.

 

vloney whats the main reason for injector failures. Poor fuel. neglected maintenance poor design off the injector. I have had diesels that have never have had injector failure through the life off the motor. I am just trying to educater myself a bit.

 

Did the tech look for the cause of the injector failure? If all you got for your money was the injector replaced without the tech looking for the cause you need a new better dealer. We are a long time past the early 03 injector problems. and without starting a debate about this, many C94's died because of poor installation. Now, has someone run a test on your fuel system? If fuel preassure drops below a certain level your injectors will self distruct regardless of the model.

RoyC

 

the early injectors had a flaw inside, the piston was slamming into the body of the injector causing failure. The redesign fixed this. I would say the primary causes of failure today---fuel pressure---fuel quality---poor previous repairs. The poor installation royc mentioned was a result of using incorrect tools to torque down the injector.

 

That is not good.

 

Alot of injector failures are also due to poor fuel filter maintenance and excessive oil change intervals. Fuel pump failures, poor fuel quality and the accidental gasoline in the fuel tank can also contribute. I just had an '03 with a combination of 6 failed and weak injectors 2 weeks ago, I asked Ford if I could put in all 8 while I was in there, and they declined. Gotta save the buck you know...

 

True, but lets not forget the first injectors (pre C94) were rejected by FMC and IH had to pull all of those out of the already assembled engines in an non-production environment, with mandatory overtime employees, employees who are union and just had a bitter contract approved by something like 51 to 49 percent ... And you wondered why I waited until after three months of engine production had been installed by FMC before I ordered my 2003 X.

RoyC

 

The C-94 suffered a spring side load to the injector pin. All C-94 injectors were used in production until the supply ran out. The C-95's arrived into production models in May of 03. No date is specified, the only way to know is put one in your hand.

 

Ok is that what lead to engine being pumped full off fuel an locking up on the early o3s or is itjust a case where you lose power if there bad. Anybody clarify?

 

thats the spring side load and piston problem mentioned earlier. The injector would literally break apart. Its occasionally happening even today. The fuel inside the injector acts as a dampener for the piston action. Thats why fuel pressure and quality is so important.