Ford Doctor
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Everything posted by Ford Doctor
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From the album: Fuel System Failures
Yet another 6.0L fuel injector has come apart. The control valve body fasteners failed causing the injector to come apart© Keith Browning
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From the album: Fuel System Failures
A 6.0L fuel injector with it's spool valve retaining bolt and nut missing. The parts were retrieved from the cylinder head where they were laying.© Keith Browning
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From the album: Fuel System Failures
This 6.0L injector tip is split wide open. While it apears to have been in contact with a piston the failure injector tip fractures are known to be caused by dry starts and there is also a theory about water in the fuel causing this.© Keith Browning
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From the album: Fuel System Failures
A 7.3L fuel injector with what looks like heat damage. Actually the hole in the injector body was caused by an internal high pressure leak which blasts a hole through the side of the injector. You might compare this to how a CNC machine cuts metal© Keith Browning
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From the album: Fuel System Failures
From a 2003 6.0L high pressure oil pump this rotating cylinder shows cracks that caused low oil pressure. The condition was a crank/no start when hot. The High Pressure Oil Pump is a fuel system component.© Keith Browning
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From the album: Fuel System Failures
Some non-OEM fuel filters require making modifications to the filter stand pipe. Here the insertion of a plastic ring has damaged the bypass valve which is actually missing from the center.© Keith Browning
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From the album: Fuel System Failures
Relaminating fuel tanks is a viable option and much more cost effective than installing a new OEM tank and possibly more reliable in the long run. This is the same tank as the previous image. There are a few companies performing this service. A little research might be worthwhile.© Keith Browning
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From the album: Fuel System Failures
You are looking at the inside of the infamous aft-axle fuel tank found on many Super Duty trucks. Sources state that fuel additives and bio-diesel cause the lining to fail but looking at this image it is hard to agree as chemical damage would affect the entire surface of the tank, not just the edges and top surfaces.© Keith Browning
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From the album: Fuel System Failures
Signs of water in the fuel show up in other places as well. This 6.4L fuel injector has rust on its outer body. Internal damage has likely occurred. Once again, damage to the rest of the fuel system is likely and not covered under warranty© Keith Browning
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From the album: Fuel System Failures
This 6.4L High Pressure Fuel Pump is telling a story. The rust on the inlet and outlet fittings indicates water has entered the engine fuel system which is extremely bad. Water will do damage to the highly sensitive fuel system in these engines. This is not warrantable.© Keith Browning
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From the album: Fuel System Failures
The most common customer induced issue is fuel filter neglect and these filters had an extended service life. Fuel filters are usually the first thing a diesel owner will try when their truck has driveability issues but in cases like this damage to the fuel system has been done. Regardless of fuel filter condition fuel pressure testing a must.© Keith Browning
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From the album: Fuel System Failures
A 6.0L HFCM showing the unmistakable evidence of a rusted fuel tank. This much debris means that extensive damage to the entire fuel system has occurred. You will likely need to replace everything in the system including all 8 fuel injectors, both fuel pumps, engine lines, fuel cooler and filters as equipped.© Keith Browning
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From the album: Fuel System Failures
This 6.4L HFCM has a greasy build-up in the water seperator chamber believed to be paraffin from the fuel. If you encounter a vehicle with a water separator drain that will not drain with the valve open or the water in fuel lamp stays on continuously check for this condition.© Keith Browning
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From the album: General Mechanical Failures
What could have started as a burnt valve, a nice chunk if this exhaust valve has broken off and become embedded into the cylinder head. Typically broken valves create a more spectacular amount of damage as the parts bounce around in the cylinder and break up and embed themselves into the piston.© Keith Browning
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General Mechanical Failures
Images added to a gallery album owned by Ford Doctor in Technical Photos
Regardless of how good or unreliable any engine proves to be there will always be some failures. With millions of engines produced some patterns have become evident but there are also the random and odd failures that make things interesting. -
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From the album: General Mechanical Failures
Here is the back of the turbine wheel of the 6.0L turbocharger shown in the previous picture. In the center you can see the effects of severe heating - the bluish, purple color of the metal. As the shaft fatigued and began to come apart the outer edges and the fins of the wheel contacted the turbine housing. This part was retrieved from the exhaust downpipe about a foot down from the turbo.© Keith Browning
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From the album: General Mechanical Failures
This is what can follow a turbo shaft bearing failure. Early build 6.0L engines were susceptible to turbo oil seal and bearing failures due to fuel dilution of the engine oil. The turbo seals were quickly updated with more fuel tolerant seals and the leaking fuel injector body concern was also quickly corrected.© Keith Browning
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From the album: General Mechanical Failures
This 6.4L Power Stoke suffered multiple cylinders with low compression due to fuel washed cylinder walls. The fuel system had evidence of water contamination resulting in injector failures and over fueling which can dilute the oil film on the cylinders reducing lubrication. The result is worn and sometimes polished looking cylinders. While the metal should always be bright and shiny with a machined crosshatched appearance, it should not appear to have a mirror-like finish with little or no machining marks.© Keith Browning
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From the album: General Mechanical Failures
There are times when damage to a cylinder is not spectacular or even very obvious. Look closely at the left side of this piston crown and you can pick out the melting around the edge that was occurring. Even more difficult is determining the cause. Was it caused by un-metered fuel in the cylinder from an injector concern or excess fuel diluted oil from the crankcase breather system coming through the intake? Over loading and over heating or the use of a non-factory engine calibration?© Keith Browning
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From the album: General Mechanical Failures
This cylinder in a 6.4L Power Stroke was damaged by a missing piston wrist pin retainer clip. Since the wrist pins float in the pistons and connecting rods the cylinder wall was damaged as the wrist pin moved and contacted it. The result was two large wear lines and an increasing loss of compression.© Keith Browning
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From the album: General Mechanical Failures
There are a few things possible here. The piston crown shows signs of melting which commonly leads to metal transfer from the piston to the cylinder head. The cause of this is over fueling either due to an injector failure of some type or unmetered fuel entering the cylinder. Unmetered fuel can be the result of high crankcase oil levels due to fuel dilution. When this occurs oil ends up in the intake and fed to the cylinders. In a worst case scenario an engine runaway situation can occur and when an engine over speeds the valves can float contacting the pistons.© Keith Browning
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From the album: General Mechanical Failures
Another 6.0L engine that met a violent end. What you see here is a connecting rod cap that knocked a hole in the side of the cylinder block and came to rest on the upper oil pan.© Keith Browning
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From the album: General Mechanical Failures
The remains of a broken piston always end up in the pan along with other moving parts in the crankcase. Yup. More shock and awe. If you look carefully you can see piston bits, piston rings, a piston cooling jet...© Keith Browning
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From the album: General Mechanical Failures
A 6.0L missing a piston. Number 5 to be exact. Well, we know exactly where it is. It is in the oil pan in many pieces.© Keith Browning
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From the album: General Mechanical Failures
A look at 6.4L rocker arms. On the left the tip is missing and you can see the wear inside the cup. on the right the tip is still there however it is badly worn and recessed into the rocker. Inspection also showed that the tip no longer freely moved in the cup. During any tear down and inspection this is one area to be sure to inspect and it warrants looking at ALL of them. The rockers are best serviced as an assembly because this type of wear typically will be found at more than one cylinder if not all of them.© Keith Browning
