2004 Fuel Water Separator help? - Ford Powerstroke Diesel Forum
Please Visit our Site Sponsors
6.0L Problems Forum Having Trouble? Post here

Powerstroke.org is the premier Diesel Truck Forum on the internet. Registered Users do not see the above ads.
LinkBack Thread Tools Display Modes
Old 08-19-2009, 11:02 AM
Powerstroke.org Rookie

Join Date: Jul 2009
Posts: 4
Thanks: 0
Thanked 0 Times in 0 Posts
Feedback Score: 0 reviews
2004 Fuel Water Separator help?

Hi All-

I recently purchased a used 2004 stock F350 with the 6.0L. Great so far...

Only two minor issues -- about 2-3 hours after leaving the dealership, the water in fuel light came on. Of course, I suspected water in fuel -- there is a crappy little gas station right next to the dealership that they use to fill for test drives. My guess was that they didn't sell very much diesel...

So, I grabbed my hex wrenches and went hunting for the drain plug. Turn, turn, turn -- keep turning -- the drain plug just rotates freely inside the hole. There is no leakage. Eventually, with a little rocking back and forth, I was able to get the drain plug out. Maybe 4-5 drops of water, but the rest is clean fuel and it was dripping very slowly. Was able to re-insert the plug and no leaks. Bad news, after I start the truck back up, about 30 min later, the water-in-fuel light is back on...

1: Is freely rotating plug normal? Seems to me like the threaded part of the plug was stripped or something -- but not sure.
2: What is the plug supposed to look like?? Are there threads on the tip?
3: After I get the plug out, how quick/slow is the flow supposed to be?
4: If I have a water-in-fuel indicator lit, how much water should I expect to come out??
5: Could this be a bad water-in-fuel sensor?
6: Do I need to replace the entire fuel filter/water separator assembly if the threads in that hole are stripped?

Second issue -- when I remove the fuel filler cap, I notice that there is a rusty residue from the lip of the opening to about 2" into the fuel fill neck. It is a very fine "dusty/muddy" rust, not big chunky/flakey rust. How can I safely remove this??

Thanks for your help!!
Reply With Quote Quick reply to this message
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Ford Powerstroke Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
What state or province do you live in?
Security Question
*Required, this field is not shown to others. Enter the last two characters of the word "Powerstroke"
Security Question #2
*Required, this field is not shown to others. "While balancing on a piece of wood, two inches by four inches known as a 2x4, john and his friend sally both spotted a dalmatian inside a truck with sirens, headed to put out a fire. State the animal mentioned in the sentence above."
Please select your insurance company (Optional)


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

All times are GMT -8. The time now is 08:35 AM.

Powered by vBulletin® Copyright ©2000 - 2015, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.1
Garage Plus, Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.