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Thread: Ford 6.0 diesel hpop fix

  1. #1
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    Default Ford 6.0 diesel hpop fix

    For those poor slobs that actually purchased this truck and therefore engine one of the many system failures is the high pressure oil pump spits out it's low pressure side plug,,, i don't even know what the original looked like cuz its laying around in the bottom of the oil pan,
    but anyhow - I guess this is a common problem (along with many other common problems that these overcomplicated piles of junk have)
    the fix simply involved machining a new plug and I went with aluminum cuz that's what the pumps housing is built of and wanted to keep the same expansion ratio with the various temperatures - there was not enough meat to pipe plug tap it otherwise I might have but one wall was kinda shallow - the bore was oval from .475" to .477" so I just made the plug .477" and it went in tighter than a mo-fo --- so tight I had my concerns about that one shallow wall but got it in and about .025 under flush and then peen'ed the housing material over the plug some ------ can't see it ever coming out again unless the housing cracks.

    anyways - If any of you guys ever have a no start or idle only situation with one of these trucks do check out the driver side of the pumps housing and make sure that the plug is still there, the engine will behave slightly better when cold and the oils viscosity is still thick but as soon at it heats up it will not even idle in most cases...
    Last edited by A.K. Boomer; 07-07-2011 at 11:55 AM.

  2. #2
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    Ford's good 'ol "Powersmoke diesel". The engine that Ford sued International over. International (Navistar) got a real black eye over that one.
    Yes, the plug has a tendency to blow out, among other things. You haul it into a Fraud dealer, and their "diesel specialists" will happily tell you that you need a new pump,($$$) and won't even look for the plug.
    Ever wonder why they have so much trouble with the hydraulic control circuits on a "Powersmoke"? The main reason is; the pump is fed unfiltered oil from the sump. If you let your oil get dirty or overstay it's welcome, problems soon follow. The only guy I know that has never had a problem with his "Powersmoke" runs an auto parts store locally, and just happens to be the local Amsoil synthetic oil distributor. He has used Amsoil since his truck was new. Expensive, but he hasn't had any problems with it...yet.
    No good deed goes unpunished.

  3. #3
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    I love my 7.3!

    That being said lots of the 6.0 problems are because ford got the motor and said that isn't good enough and turned it up when they put them in their trucks. Then a bad EGR system to boot so if you didn't stretch your head bolts and blow a gasket you got a plugged EGR system.

    They say they are perfectly good engines after doing ARP's and EGR delete. Even still I will never have one and the way it looks I may have to keep my 7.3 forever.
    Andy

  4. #4
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    Quote Originally Posted by saltmine
    Ford's good 'ol "Powersmoke diesel". The engine that Ford sued International over. International (Navistar) got a real black eye over that one.
    Yes, the plug has a tendency to blow out, among other things. You haul it into a Fraud dealer, and their "diesel specialists" will happily tell you that you need a new pump,($$$) and won't even look for the plug.
    Ever wonder why they have so much trouble with the hydraulic control circuits on a "Powersmoke"? The main reason is; the pump is fed unfiltered oil from the sump. If you let your oil get dirty or overstay it's welcome, problems soon follow. The only guy I know that has never had a problem with his "Powersmoke" runs an auto parts store locally, and just happens to be the local Amsoil synthetic oil distributor. He has used Amsoil since his truck was new. Expensive, but he hasn't had any problems with it...yet.
    There was a TSB issued on the hpop failures some time ago.

    saltmine, you are spreading erroneous information. Here is a schematic of the of the oil system in the 6.0.

    As you can see the oil is passed through the filter before the hpop. The 6.0 Bible is available for anyone to search and download. I could send you a copy but it is a large file.

    I am one of the poor slobs that owns a 2003 with no engine problems to date.
    It amazes me at the misinformation out there on the forums about this motor.

    be
    Last edited by bewards; 07-01-2011 at 09:04 AM.

  5. #5
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    Yea as far as I know the oil is filtered - there is no reason to have it otherwise but then again there is no reason to have high pressure oil in the first place - yet they did it, there's also no reason to have high voltage injectors that are controlled by a thirteen hundred dollar "brain box" (and that's the cost of a remanufacture'd) yet because they started off with a bad idea they had to keep it going so they did,
    So what you end up with is a complicated system coupled to a complicated system that is yet coupled to another overcomplicated system and all of these systems have a multitude of failure points and when it comes to just the HPOS all it takes is one of the near over 50 seals or O-rings or O-ring retainers or fittings - or main components that consist of a plethora of individual parts to fail and then the entire system goes into a failure mode, Keep in mind that all these seals and O-rings and pressure related parts are under a constant state of flux - the HPOS operates anywhere from around 800 psi to close to 4,000 psi The O-rings are not static - they are under a constant state of physical change with these varying pressures - and almost every single one of them is not easy access and in fact I might add not fun to get to in most cases --- This entire engine is a piece of crap, it never should have been built and whoever designed this POS should be pushing a broom - In all my years I have never seen anything like this, and don't forget Im the guy who's worked on a few mitsubishi's in his day, This engine has cost Ford dearly in reputation and yet ford owns the rights to the cummins which is superior - go figure...

    The 7.3 has many improvements and it's failure rate drastically reduced, but still what your left with is a bunch of systems relying on other systems, and what for? are they more efficient - no - they get worse fuel economy, are they more powerful - nope, so what do they do right? well - they line the pockets of all the parts companies and dealers associated with them that's what they do right, their crap...

  6. #6
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    I have an 03 6.0 badged as a 2004. I replaced the head studs and installed an EGR delete (first coast). All has worked pretty well since those two mods. The HPOP does seem to start leaking about once a year. Otherwise the 6.0 is a viscious motor. I run an SCT custom tune "extreme with propane". To date, not 1 (diesel, new or old, dodge, ford, chevy modded or not) truck has ever been able to keep up on the street. Not bragging that is just how it has been so far (since 2004). I am thinking it is time to go to Baytown to Houston Raceway Park just to see what its good for.

  7. #7
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    Quote Originally Posted by A.K. Boomer
    The 7.3 has many improvements and it's failure rate drastically reduced, but still what your left with is a bunch of systems relying on other systems, and what for? are they more efficient - no - they get worse fuel economy, are they more powerful - nope, so what do they do right? well - they line the pockets of all the parts companies and dealers associated with them that's what they do right, their crap...

    The 7.3 was before the 6.0. The newest ford diesel is the in house built 6.7.


    it went: 6.9 - 7.3 - 6.0 - 6.4 - 6.7
    Andy

  8. #8
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    I'm glad you straightened that out. I got my info from a guy who works on Ford (International) diesels eight hours a day, five days a week, and assumed he knew what he was talking about. Sadly, the auto industry is rapidly running out of skilled mechanics.
    But, I also failed to mention that International (Navistar) does not have problems with the very same engines. International claims the high pressure control system was Ford's idea (an effort to copy the GM Duramax, but the Duramax was designed and built as a high pressure control engine, from the start, not modified and added to it. They also claim numerous failures were due to the high pressure control system breaking down the oil with extremely high shear pressures (which GM or Cummins don't have)...BTW, Ford blamed the oil breakdown on vehicle owners (erroneously) not changing the oil frequently enough.

    When I worked in the County fleet shop, we had a steady stream of Fords going to & from the dealer for warranty repairs...they were all diesels.
    And, even though I retired in 2006, the shop still has one guy whose sole job it is to ferry Ford trucks back and forth to the dealer. My diesel specialist friend now tells me that since Ford has stopped using the International diesel, and has designed and built their own, the new ones are starting to crowd into the shop, with problems of their own.
    Having worked at the Ford Yucca Proving Ground, after I retired, until Chrysler purchased it, we were testing the new diesels. I remember vividly one of the drivers calling on the radio, requesting an emergency vehicle, because the truck she was driving had "backfired" and now there was a huge dent in the truck's hood. When they got it back to the shop, we discovered the entire turbo assembly had blown off of the engine, and smashed into the hood. (BTW, this was the 6.4 diesel with dual turbochargers. None of the drivers liked to drive the 6.4 test vehicles because of the numerous exhaust leaks that filtered into the cab of the truck while driving, making almost anybody who drove them very sick.) They also demonstrated an enormous appetite for diesel fuel, and poor highway performance (Most cars and trucks we tested could get up to speed on the 5.2 mile test track before the first turn, starting northbound, on the front straightaway. The 6.4's required 1/2 to 3/4 of a lap to reach 80 mph. The only other vehicle that had similar sluggish performance was the Mazda Tribute (Ford Escape Hybrid). Many a night or afternoon was spent roaring around the bottom lane of the track trying to get one going fast enough to move up to the next lane and testing speeds. Sometimes, low fuel forced one to return to the fueling island without getting up to test speed. One poor soul had to refuel four times during his shift, and never got the Tribute going fast enough to test.
    Last edited by saltmine; 07-01-2011 at 10:52 AM.
    No good deed goes unpunished.

  9. #9
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    Quote Originally Posted by bewards
    As you can see the oil is passed through the filter before the hpop.
    If you let your oil get dirty and the pressure across the filter rises doesn't dirty oil bypass the filter though?

  10. #10
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    On a side note: The 7.3L diesel engine was a good power plant, but it was heavy, had a poor power-to-weight ratio and emissions wise, very dirty.
    Ford decided to use the International engine instead of attempting to "clean up" the 7.3. Many people feel this was a huge mistake.

    BTW, Fastest1, the "EGR delete" you mentioned is not 50 state legal. But, on some engines you have to break the law to keep from breaking the engine.
    No good deed goes unpunished.

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