6.4 Failure at 62k miles

[Dieseltechman]

This is what it looks like when the HPFP fails on the 6.4
I removed it myself when ford said that it would not be under waranty because of numerouse bull sh#$ reasons. Funny thing is all the damage is on the crank case side of the pump and none on the high pressure pistons. like 1 would expect if it were fuel quality or water that caused it.
Looks to me like the follower return springs broke under fatigue and got into the motion of the pump. When i pulled the pump cover, 1 of the pump heads was competely blown off the pump all 4 head bolts snapped off.

Has any one else seen this happen on the HPFP.
I think there is a seriouse problem with these pumps!

[buffalo123]

looks to me like that should have bin waranty. havent seen that before. f;;ken dealers. what kinda tuner were u running.

[sinner6.0L]

holy **** man you did that with the cab on? how fun was that? I've never seen one failed in that manner but i've have numerous control valves sticking


any signs of rust anywhere in the pump? what did your fuel filters look like when you took the truck to the shop? There has to be a reason they denied you a repair

also, with that kind of pump failure I'd be worried about metal in the high pressure lines possibly getting into the injectors

[Dieseltechman]

no tuner all stock, my dad's truck. and no sign of rust in pump at all, no heat damage from lack of lube and no scoring in pump chambers. Just lots of metal in pump crank case.

Also i traced fuel galleys in pump and all the debris should be post high pressure pump feed meaning all metal material should have gone to return to tank.
I really think the return springs that you see in the pics broke and caused all the destruction.

I have been a diesel tech for 7 years just not on the auto side, this was the first time into a 6.4 took about 7hrs to get the pump out cab on.

I will try to deal with ford this next week, they know there is a problem they just can't admit it. I will keep posting the results.

[96cobra10101]

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[Dieseltechman]

I have the pump taken apart in my garage so if anyone wants to see any more pics just let me know. I looked everywere on the web before i started to try and prepare for this job and found very damn little. Powerstroke.org had about the most info as anyone so i created an account and brought you all the info on this problem i could discover you know since Ford won't tell you sh$@. I will get to the bottom of this, failure analysis is what i do.

[blueovalman14]

[m-chan68]

[Dietoremain]

[TEX420]

Thats a chitty situation. Guess that means time to upgrade? If you have more pictures post them up if you could!

On a side note: What all was removed from the engine bay to get to that point? It seems like this is happening alot and I would like to be able to know how to do this if the need arises. I havent been a diesel tech for very long but I know a thing or two