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Old 03-19-2010, 06:21 PM
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Exclamation Water In Fuel - CORROSION

I need some advice, and I know that someone out there can give me some input on this situation.

About two months ago I noticed the "Water In Fuel" light for the first time. I spoke with a guy at work, and he told me just to put diesel treatment in my tank, and that the problem would go away. The light would come on a few minutes after I started my engine, and when I would reset the codes, it wouldn't come back for a while. Of course all this was before I knew about the water separator under the driver's side door.

I noticed corrosion in my fuel tank filler neck yesterday at the gas station. That got me extremely concerned, so I did what any normal dude would do...sign on to powerstroke.org and do a quick search. Thats how I found out about the water separator.

Well....I climbed under the truck and pulled the drain plug. I took the o-ring off and cleaned it up a little for the pictures...look at all of that metal loss.





WTF??? Has anyone else had this happen?

Here are some pictures of the filler neck:





And this is what I got out of my fuel/water separator...notice the rusty water in the fuel, and the debris floating around in there.





I am at a loss...what do I need to do???
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Old 03-19-2010, 08:24 PM
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Wow that has to be the worst one I have seen. Do not put that stuff in the tank to push the water through. You will be buying injectors for sure. I would drop the tank. Clean out the tank and lines. Then replace the fuel filters. That would be a start.
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Old 03-19-2010, 08:33 PM
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Wow, my light has been on and off as of lately. I replaced both filters and drained some fuel but no change. My next step is to pull off my sensor and check that. The drain plug is seeming to strip out by using a 6mm hex, so i just pulled the entire plate off before. I heard the sensors corrode often and need to be cleaned/replaced. Good luck getting this all cleaned up and working good again.
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Old 03-20-2010, 02:08 AM
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It may be a little costly, but I would drop that tank and not use it back. If you love having your motor running i would get a new one or a good used one. As fr as diesel treatment, its not for anything like that. I've used power service treatment in my truck every tank since new and CETANE every other. Makes a huge dfferece. I also change my fuel filter, seperator fliter every 5k miles religiously. That orange stuff in your pic is water and thats what corroded your plug. I know at least 5 friends that were told by Ford that a defective batch of tanks had come out that rusted and grew mold. I thought it was pre 6.0 era though. good luck
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Old 03-20-2010, 02:32 AM
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I'D GET A NEW TANK PLUS FILLER NECK .WOW
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Old 03-21-2010, 07:20 AM
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My first step will be to change the fuel filters again in 1000 miles. See how they look at that point.

quequeg37...I do love having my motor running!

If I still have a issues in 1000 I am going to drop the tank...never done this before, so I really don't know what I am getting myself into.
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