Engine oil over-full

[Jeepman401]

Just a bit of backround info
The truck is my fathers- used for construction, sees moderate to heavy loads on a fairly regular baisis
I am a Ford Tech, currently working at a dealership, however, I am not current on my diesel, and know very little about the 6.4

Since about 4000 miles, the truck has had an issue with the oil level.
We brought the truck in, ran through the routine of pulling the valve covers, and checking for fuel leaks. Nothing found
After calling techline, the said that they were seeing a lot of cases of the oil being overfilled from the factory (BS, because I did the PDI, and I know where the oil was). The truck was needed, so we went with what ford said, and put it back togeather, knowing I would be able to keep track of it regularly. The oil was changed at this time

When my father took a vacation, I took the truck in again, and at fords reccomendation, went through the process of checking for leaks once again.
again, nothing was found, the truck was put back togeather and shipped.

The truck seems to constantly be in regen whenever I see it or drive it.

I pulled an oil analysis and sent it out at 5600 miles. At this time the oil had rose over the point where for considers it overfull, which is if you let the dipstick rest on the bottom of the plastic instead of sliding it in all the way, and the oil is over the full mark. At this point, we dumped the oil, and filed it with new oil (the old oil has been saved)
the analysis came back with fuel contamination and viscosity flagged
fuel contamination 2.9%
viscosity@100'C 11.9cst

the oil was again dumped and a sample pulled at 8600 miles, the oil was once again overfull,
fuel contamination, viscosity, iron, and aluminum were flagged
fuel contamination 5.8%
viscosity@100'C 8.4cst
Iron 25 ppm- up from 18ppm in the previous sample
aluminum 21 ppm- up from 14 ppm in the previous sample

not flagged, but also up in the second sample were
molybendum (6ppm from 2ppm)
nickel (1ppm from 0ppm)
manganese (1ppm from 0ppm)
sodium (4pm from 2ppm)
boron (27ppm from 9ppm)

Today, I took the truck in to dump the oil again, and found that we had recieved word from ford that the truck was completely normal and not to do anything more to it, and that the dealership was responsible for the 2 times we dumped the oil.

There is no doubt in anyones mind at the dealership that there is a problem, but now we cant go any further with it, or we risk loosing the money that gets spent on the truck.

At this point, I am going to change the oil on my own dime, and take another analysis.
The factory interval says 5k, 10k, then every 10k after that, so Thats what the truck will get. the oil can rise all it wants, and if it makes it to 20k, I will do the same. In the meantime, we are trying to go through with lemon law.

anyone else running into problems with ford refusing to admit the truck has a problem? if so, how did you go forward with it?

[vitalidle]

I don't know anything about the 6.4, but typically if you find diesel in the oil its from bad orings on the injectors, but since the 6.4 is common rail and not fired from high pressure oil thats not it I would suspect

[Jeepman401]

Unfortunetly, its not a direct leak from a injector, we suspect the reason is the truck being constantly in regen

[vitalidle]

Has it had all the software updates to the pcm?

[redpony69]

I am a ford master certified diesel tech. I have seen this on a couple of trucks now. Have you checked for any recalls? Also try using oil dye in your secondary fuel filter housing, run the engine for a few minutes and then take the valve covers off. It is not possible for o-rings to leak. I would suspect the short fuel lines from the fuel rail to the top of the injectors. Hope this helps.

[longhorn 6.4]

What is the pcm?

[vitalidle]

Thats the computer or Powertrain control module. Here is a list of acronyms for you Common Acronyms

[longhorn 6.4]

Thanks man.

[vitalidle]

You bet

[powerstrokes only]

This really disappoints me! How can Ford call that normal? I say run the crap out of it and let it blow up or do what ever damage it has coming and let them deal with that!