Injector top o-ring and spacer issue - Ford Powerstroke Diesel Forum
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Old 08-03-2014, 02:40 PM
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Injector top o-ring and spacer issue

Last week I pulled my camper for a week long vacation. Made it to the campground fine... the truck did great job as usual. The 2nd day I went to Wally World and the truck lost ICP pressure and broke down. Got pulled back to the campground and tore into it.
It turned out to be the top of an injector. Looked like the retainer clip gave up and let the o-ring and steel spacer slam up the nipple cup. The Retainer clip was out of shape and the spacer ring was split in half. All three pieces were at the top of the nipple where it flanged into the ball cup.
I got a new injector and put it back together. You can imagine how fun that was away from home without your tools and shop.
A week later we leave and come home just fine. The next day at home I was running an errand and the same thing happens. Different injector... same exact findings. WTH is causing this.
It's the same scenario of hard pull of the camper, pulls fine and then when not loaded.... next day the top of the injector blows apart.
I need to find where to get that steel spacer. I have the o-ring kit (ISK-102) but it doesn't have that piece.
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  #2  
Old 08-04-2014, 06:38 PM
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You may have a batch of bad injectors, this was a special service message pertaining to 2005 model years.

Are all your injectors OEM originals? If they are I would consider replacing all of them with new. Your snap ring grooves may be defective.
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Old 08-05-2014, 04:47 AM
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Quote:
Originally Posted by sinner6.0L View Post
You may have a batch of bad injectors, this was a special service message pertaining to 2005 model years.

Are all your injectors OEM originals? If they are I would consider replacing all of them with new. Your snap ring grooves may be defective.
All but one is original. But all have new oring kits (Bostec) and clips as of a year ago.

Now they have all been done again.
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Old 08-12-2014, 08:45 AM
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OK
I have a theory. Let me know what you think.
Not long before I had the problem with the busted retainer clips I worked on another issue. I had a "hot no start" and stall.
Found an o-ring on the passenger side that had failed. Put back together. When I first started the truck it ran rough as expected. I tried to rev the motor to work out the air. When it didn't clear up I read the codes and I found that I did not fully re-install one of the plugs back into the FICM.
I'm wondering if since I had good ICP pressure and the injector wasn't firing... would that have put enough pressure on the top O-rings to force the retainer clip to fail? It was all the injectors on the drivers side which is where my issue has been.
Since then I have replaced all the tops of these injectors and it's running fine.
It will make me feel a little better if I feel I know what caused this to happen.
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