New fuel system failed again in 15 minutes

DEEZUZ · Aug 28, 2012

Had a 6.4 come in, low contribution on a cylinder or two. Did the ole fuel sample from feed tube. Sure enough, brass particles which I was told is the HPFP coming apart.

I replaced and cleaned EVERYTHING

NEW
HPFP
HFCM
Both rails
8 feed tubes
8 Injectors
Fuel supply lines
Fuel return line
Fuel Cooler

I also blew out any lines left over and dropped and hand cleaned the tank. Cleaned secondary filter housing, removing standpipe. Filled the system up with CLEAN fresh fuel. Bled out the system through the fuel cooler. Finally got it running and took it for a ride. Instantly I had almost 0 throttle response. My SFT's were from -5 to +11. All injectors bad again. I took a sample at the fuel cooler and sure enough, SAME brass/copper particles...

Any idea on WHY the pump failed again or if maybe there is another source of the gold particles?

TyCorr · Aug 28, 2012

That's ***ked up!

weekendwarriorfsw32 · Aug 28, 2012

OEM parts or GPD reman parts?

6.0 p-stroke · Aug 28, 2012

Couldn't that be a sign of bearing material? Not sure how it'd get in the fuel system though

DEEZUZ · Aug 28, 2012

Yea your telling me... On the phone with Ford Tech and they said I went above and beyond, this shouldn't have happened. But even they couldn't tell me the source of the shiny gold pieces...

I tore the old HPFP apart to find the source. It seems to me the bushings/bearings they use to hold the camshaft are made out of or coated in this gold stuff... But it didnt look tore up at all. The pump has no signs of rust either...

DEEZUZ · Aug 28, 2012

EVERYTHING OEM. Not a penny pinched

DEEZUZ · Aug 28, 2012

http://www.forddoctorsdts.com/articles/article-10-03.php

Minus the grey matter, that sparkly **** is what Im getting, and alot of it...

weekendwarriorfsw32 · Aug 28, 2012

There is a chance that you got a bad pump from the factory, if you cleaned all the lines out the best that you could then a pump would be the only thing. Did you cut apart the fuel cooler by any chance?

DEEZUZ · Aug 28, 2012

Well I know the old system was full of debris, why would I cut apart the cooler?

I was thinking maybe a bum pump, but the chances are rare. Ford told me I could take it to a dealer and have them tear it apart. Might be covered. But we'll still be out 8 injectors, rails, lines, and not to mention a fuel tank that takes 3 hours to pull down(special body)

weekendwarriorfsw32 · Aug 28, 2012

The lining of the cooler I thought was brass, I could be wrong but tomorrow i will cut a just one up and see. But it does not make since for a brand new one to come apart like that.

CTC DEEZUL said:
Well I know the old system was full of debris, why would I cut apart the cooler?

I was thinking maybe a bum pump, but the chances are rare. Ford told me I could take it to a dealer and have them tear it apart. Might be covered. But we'll still be out 8 injectors, rails, lines, and not to mention a fuel tank that takes 3 hours to pull down(special body)

DEEZUZ · Aug 28, 2012

Hmm, never heard that one. Let me know

78f100 · Aug 29, 2012

do you have to replace the whole injector or just the nozzle?

DEEZUZ · Aug 29, 2012

entire injector.

capt dong · Aug 30, 2012

this will probably sound silly but maybe theres really bad contaminated fuel still in the tank.

me2 · Aug 30, 2012

CTC DEEZUL said:
Had a 6.4 come in, low contribution on a cylinder or two. Did the ole fuel sample from feed tube. Sure enough, brass particles which I was told is the HPFP coming apart.

I replaced and cleaned EVERYTHING

NEW
HPFP
HFCM
Both rails
8 feed tubes
8 Injectors
Fuel supply lines
Fuel return line
Fuel Cooler

I also blew out any lines left over and dropped and hand cleaned the tank. Cleaned secondary filter housing, removing standpipe. Filled the system up with CLEAN fresh fuel. Bled out the system through the fuel cooler. Finally got it running and took it for a ride. Instantly I had almost 0 throttle response. My SFT's were from -5 to +11. All injectors bad again. I took a sample at the fuel cooler and sure enough, SAME brass/copper particles...

Any idea on WHY the pump failed again or if maybe there is another source of the gold particles?

Did you replace the fuel filter housing ?

My 6.4 had this same problem and Ford fixed it under warranty back in spring. I can look up what exactly they replaced if you need me to. I also have the 08 shop manual which probably goes into some detail as well.

PM me if you don't figure it out.

SootRoller · Aug 30, 2012

Did you back flush the heads with the old injectors in? There was a video from ford on the procedure a while back. Not just blow them out with brake clean, I mean run the diesel through the heads like it states in the wsm then finish cleaning them with a rifle bore brush. That's how I do every last one.

DEEZUZ · Sep 6, 2012

did not replace housing, but removed stand pipe and cleaned it.

did not backflush, was not aware there was a procedure. But I dont understand, thats the return side, goes back to tank... filters should be catching this stuff... the debris is huge