Hi All,

I need to change out the injector cups in a 95 dually because of oil and coolant mixing. Any idea how long this SHOULD take, I've never done it before and don't know how long to tell the owner.

 

Symptoms of a bad cup , are ,usually fuel in the coolant. You may want to test the oil cooler ....

It depends on who you ask on the time ,

 

Look Here ....Injector Sleeve Puller | Ford 7.3 Powerstroke Diesel Engine Tools | Whitaker Tools, Inc.

The heads don't have to be removed ,no matter which way you pull the cups ...

 

Yeah, thanks for the heads up on the fuel/coolant. I know that's the normal symptom. Just had the oil cooler out and o-rings replaced for external leakage. I think it's next to impossible to have one of those orings slip or be misplaced. Took two of us to get the ends back on because of how rugged they are. Anyway, Rechecked an no leaking down there, it's up high in the engine.

I guess on that note, any other suggestions on oil mixing with coolant, coolant in oil? The symptom is sludge in the valve coves clogging the breather. This forced the dipstick to pop out. Valve covers were just off recently for injector upgrade and were clean at the time. There is no coolant sludge in the oil filter, oil in the pan, dipstick is clean! Radiator has oil (at least) sitting on top of the coolant and the coolant was low.

Thanks for the link, that gives me an idea.

 

Well, I don't see how a bad injector cup could cause coolant to get into the oil. The cup appears to only cover the fuel gallery, not the oil gallery too.

 

I'm thinking hard on how the oil can get into the coolant on our trucks, and I cannot come up with anything simple. But then, I dont know much about it.

The other stuff you replaced coulda done some stuff like that.

The EGR Coolers on the 6.0's leak and get oil in the coolant.
They rust out and let the oil flow up inside the radiator. But I don't know if that stuff is possible on our trucks, unless he's running a 6.0 radiator.

pluss with oil in there, it will take some cleaner and a flush or 2 to get that film it leaves outa there.

 

I believe the cup has coolant on the outer side and the injector has oil and fuel on the inner side.

If there is were or a leak then coolant will get into the oil when it heats up and pressurizes.

 

I made up a list of all the possibilities, that I remember, that have been reported here about oil in the coolant. Some are rare others are down right scarry:

• Oil cooler
• Injector cups
• Head gasket
• Welch plugs loose/corroded (4 plugs each head, under valve covers)
• Front engine cover (cavitation)
• Front Engine cover de-aeration valve loose/fell out (engine serial# 201681 through 375549 only)
• Hole/crack in the block coolant passages (cavitation)
• Hole in the cylinder liner (PICTURE)

 

Cuda Jim knows about this stuff I'm sure. We'll have to wait till he gets around.

 

Wow, look at that, he posted right while i was posting.

 

Now that IS scarry! haha

Chris, How are you going to quote this one.....I just had to give the same bad news to the owner of a PSD.

 

Honestly not sure yet. I know him personally too, so it's a little easier than a customer I don't know.

Right now we are in tear down time to check it out. I've pulled both valve covers and the driver side injectors. Both valve covers are covered in sludge, but no coolant leak was noticed in any of the cups. The tops of the heads look like they have been steam cleaned. A few weeks ago he put injectors in and I stopped in to check on him and the heads were much more varnished looking and he confirmed as well, so def coolant getting in there somehow and steaming off in the top of the motor. The real complaint was the oil dipstick blowing out and spraying oil all over. I noticed the doghouse breather was clogged and we removed it to find all this sludge.

Yet there is no coolant in the oil pan or mixed with the oil from the pan. We left the system pressurized for hours with the oil filter off and no coolant came out there either. When we recently did the oil cooler o-rings the cooler looked perfect too. My suspicion would be KISS and it's related to what we just did, but we would have to see water contamination into the oil in general if it was coming from the cooler. The radiator took 2 gallons of water to fill up for pressure testing so this moisture is going somewhere!

 

Does the coolant system hold pressure?
Pass side inj's pulled yet?
On a wag the coolant is getting vaporized in the combustion
chamber. This allows it to pass thru the crank case in a gas state.
The sludge starts where the gas has formed back to a liquid.

My money is on pin hole/holes in a cyl.
Then head gasket.

Bill

 

Yeah, that's going to make even harder since you know him. Hope it doesn't get too expensive for him but it doesn't sound good from your description. Good luck, keep us posted of your findings.....

 

UPDATE:

Oil level in pan rose 3/4" after being pressurized this afternoon for a couple of hours. Coolant leaking into engine. We are going to pull the heads and see what's up!

Yeah, knowing the customer personally can make the situation tough, but he is kinda a have to have it done guy but just wants to know what it's going to cost.