has anyone rebuilt their injectors internals? Or know who carries the right kit I need? Truck is over fueling bad, done all the electrical test changed icp and ipr. The injectors look good externally so I'm guessing it's on the inside mechanically, broken spring o ring check ball poppet.

 

Injector parts out the wazoo.
https://406injectors.com/collections...-3-powerstroke
hotrodfordguy rebuilt his but we haven't heard back on how it panned out. (Wish I could figure out how to utag him). I'd like to hear how you make out as I'd like to do the same but it's uncharted water around here and I'm just a little uneasy about it. I once read that a stuck injector could burn a piston and would like to hear more about the threat of that happening as well, a failed home rebuilt injector is one thing, a burnt piston is another.

 

Interesting topic. I'd love to tinker with things, just for the heck of it. Have to find a core of course..

Mark, I tried looking up hotrodfordguy and there's no user and no posts by that name, although I do seem to remember him. Is this site like Facebook, where if you delete/close your account you disappear entirely?

 

Look up Hotrodfeguy

https://www.ford-trucks.com/forums/1...ector-fun.html

 

Thanks for that, I have the goofiest memory.

 

Expacamper wants to dabble in this too, I have a full set of AD's with about 225,000 on them looking for something to do. There are some pricey tools that are needed to make it happen though.

 

I have the 8 good AD's that I just pulled from my tuck and 8 more that are from the old engine and are bad. 1 of them is damaged on the outside so I may tear one apart to see what all is going on. I bought a set from a running truck sold as cores and played the injector swapping game trying to make that engine run decent after I put injector cups in it so those 8 I have were the worst of the 16.

 

So...are you saying that for the cost of shipping you'll send 'em over so we can experiment?

 

I am going to open the damaged bad one first and see if I want to look into doing anything with them. Ill either try to redo them or sell them cheap. (the 7 other bad ones plus the one i open up) the 8 "good ones" i just pulled I am going to keep for a future rebuild either by myself or a company.

 

well, I have done some set lately and its straight forward as long as you take your time and have the tools needed to take them apart. 406Injectors have all the parts and tools for the job and I will reccomand him and his products.
I will say - based upon the ones that I have done, the internals could have different wear pattern within same injector set. Previous owner could have some new put in between the others or they wear differently. The last based on the fact that if the pintle/needle get stuck in the bore - it could cause the spring plate to wear out or wear differently and therefore I would reccomand having them ( spring plate) replaced . They cost nearly nothing.
Another thing - poppet clearance not more than .002/2 thou. If they are tighter - yes you can shimme them to higher clearance - I NEVER do it as the poppet seat and valve have worn too much. Some will do it and say it will work - I'll say having different poppet wear will cause different lifespan in a matching set of 8 - .

Also - another thing I've found necessary is to take the new injector needle out of the bore and clean well with brake cleaner before you oil lightly with motor oil and leave them in a bucket with fuel before assembly.

I have polished the Intensifier piston - in most cases small marks and pitting stripes will disappear - so the intensifier O-ring doesn't take a beating causing an internal leak.
I have also seen broken dovel pins - one broken can stall the rebuild if not in stock, lift pin damage and damage done by the lift pin to the stop/check plate. I therefore take some time during cleaning to make sure non of the internal parts are damage in any ways.
You can turn the armature plate 360 degrees - make sure it correspond with the solenoid magnet above - there are 50% chance of putting this in right/wrong position.



Test run Arendal - North Cape return with trailer both ways ( 2600 km), total weight 4.5t up and 3.8t return. I used 4 days on the trip limited to 55mph due to hauling and average fuel consumption where 19 mpg - hand filled.


Just order the parts and go for it.
Helge

38R, 4 inch MBRP, 140V IDM, S&B cold air, canned flashtune SCT, 130cc/30 injectors, AIH delete, Melling LPOP, Terminator T-500, FR-x, Hutch, Afee intake, CAC boots, HPX, OCR RR, High Flow Banjo, non EBPV,