New fuel system failed again in 15 minutes

[DEEZUZ]

No I did not... When I talked to Ford Technical support I named everything I did to this sytem. They said it was above and beyond what they normally even do...

Like I stated early, if the issue was in the return passages, why wasnt it caught in the TWO filters?

 

[dieseljosh07]

Sometimes debris can get stuck in the check valve on the return line from the heads to the fuel cooler. There's a long multi step procedure to flush the heads and return line. I believe they now recommend replacing the return line from the HPFP to fuel cooler that has the check valve.

 

[DEEZUZ]

I was actually going to, I had the part delivered, but it wasnt bent, it was like 4 foot long... I would have to believe it was made incorrect, it seriously stretched from the cowl past radiator....

 

[DEEZUZ]

Well back from vacation and this truck is first on my list.

I have gained access to Fords PTS Technical Resource Center. There I found the Workshop Manual, but have found nothing on a return flushing procedure for the heads. Any thoughts?

 

[Charles]

I'm not 100% on 6.4 terminology, so if it was in one of the acronyms then I apologize, but what caused the original pump to have a problem?

I ask because I didn't see anything about the lift pump in the diagnosis. Is the lift pump solid? If not, did it take out seimens pump number 1 and 2 with lack of delivery pressure?

 

[Dzchey21]

I'm not 100% on 6.4 terminology, so if it was in one of the acronyms then I apologize, but what caused the original pump to have a problem?

I ask because I didn't see anything about the lift pump in the diagnosis. Is the lift pump solid? If not, did it take out seimens pump number 1 and 2 with lack of delivery pressure?

Usually they won't even.run if the lift pump takes a dump

 

[PsRumors]

When my borther's fuel system took a dump they replaced the fuel tank and all lines as well. Ford said everything gets contaminated and must be replaced.

 

[DEEZUZ]

OK I found the video on the website. Basically just remove the return from HPFP and use a fluid sucker to push diesel through, removing left side plug first, than right.

Anything else should I do this time? Im definitely replacing the secondary housing since I just cleaned it last time... I think I'll replace the fuel rails and cooler again, I dont think its worth doing this a 3rd time.

 

[DEEZUZ]

I have no explanation as to why the first fuel system failed. I took the HPFP apart and there was no signs of rust at all. Just tons of debris. We got the fuel analysis done, It says its full of aluminum this time around

 

[me2]

That sucks.

 

[Marty]

Crazy man. Posting to see if you figure this out.

 

[DEEZUZ]

I rigged this up.

We have a fuel cart. I plumbed in the line and flush 5 gallons through the return system. I removed the rear plugs and put in fitting to drain.

 

[Dzchey21]

Aluminum sounds like from the low pressure pump

 

[Charles]

My Cousin had me look at his truck not long ago because it was down on power and he had already had a HPFP replacement by the dealer a few months beforehand.

In his case the lift pump was dying and the reduced fuel to the original HPFP wiped it out over time and was killing the new one. The replacement would have done the same if he hadn't verified that the delivery pressure was low before continuing to drive it with crappy response and power again. Fwiw.... he had ZERO delivery pressure at the test port and that truck was pulling trailers like that...

I didn't see it in the diagnosis, but has the lift pump been verified as solid, or not?

 

[powerlifter405]

My Cousin had me look at his truck not long ago because it was down on power and he had already had a HPFP replacement by the dealer a few months beforehand.

In his case the lift pump was dying and the reduced fuel to the original HPFP wiped it out over time and was killing the new one. The replacement would have done the same if he hadn't verified that the delivery pressure was low before continuing to drive it with crappy response and power again. Fwiw.... he had ZERO delivery pressure at the test port and that truck was pulling trailers like that...

I didn't see it in the diagnosis, but has the lift pump been verified as solid, or not?

Charles
I have a question for you, don't want to muck up the thread but your PM's are full..

Sorry OP.

 

[DEEZUZ]

lift pump was replaced when i overhauled the fuel system

 

[me2]

My Cousin had me look at his truck not long ago because it was down on power and he had already had a HPFP replacement by the dealer a few months beforehand.

In his case the lift pump was dying and the reduced fuel to the original HPFP wiped it out over time and was killing the new one. The replacement would have done the same if he hadn't verified that the delivery pressure was low before continuing to drive it with crappy response and power again. Fwiw.... he had ZERO delivery pressure at the test port and that truck was pulling trailers like that...

Great. Now I need to go check my truck for this.

 

[DEEZUZ]

3rd fuel system failed and the engine never even started everything from tank on forward is contaminated again, along with new HPFP and 8 new injectors ruined again...

no luck at all talking with the engineers at ford... the one guy said the aluminum in the fuel was from the heads... I said they were cast heads, it got quiet...

I have absolutely no one to turn to for advise. Im tossing it on the back burner or sticking a new engine in

 

[Dzchey21]

Wtf?

 

[Mdub707]

Holy crap man... that sucks.