Cracked head? hope not - Ford Powerstroke Diesel Forum
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Old 11-13-2009, 04:31 PM
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Cracked head? hope not

Hi all, new member. I have only been on FTE before this. I have a 2002 250
with a 7.3 about 150,000, not really any mods. This past summer I put in a
203* thermostat and new coolant. About 2 months ago I pulled the turbo and rebuilt and added a WW. Other than that just maintenance.
I think I might have noticed low coolant, nothing serious, in spring. I had the coolant flushed by machine (my neighbor is a mechanic and he replaced my t-stat and added new elc). About a week ago I started smelling just a hint of raw diesel. I opened the hood looked around and under and could not find a leak.
Today I checked again and saw fuel on the passenger side battery and some other areas. I figured it came from the fuel bowl drain and I have the o-ring kit to change them out, so I went to start doing the o-rings and then I noticed it....Antifreeze is over full. I opened the degas and now I know why I have been smelling diesel. I can't figure any thing other than a cracked head, I'm not blowing and smoke, just this morn. I noticed a little romp at start up. I hope somebody out there can come up with something easier and less expensive. Thanks in advance Jeff
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Old 11-13-2009, 04:35 PM
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I am a lil unclear of your symptoms... is there diesel in the coolant, or just diesel on the firewall and battery? has it been running wierd at all? any new noises?
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Old 11-13-2009, 04:40 PM
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Could be an injector cup as well...I believe those are the only 2 places where coolant and fuel could mix. I would pull the injectors and pressurize the cooling system and see if you get any coolant out of the cups....
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Old 11-13-2009, 06:15 PM
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Yes there is diesel in the coolant, enough to make it overfull to the point of overflowing .
If it is a cup, would I see white at the exhaust. How would a guy pressurize the the cooling system?
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Old 11-13-2009, 07:43 PM
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Just another side note.I have been pouring through the big ford manual, and under the cooling section it says if you see oil in the coolant it could be from the injector sleeves.
this is starting to worry me. I'm wondering if I have to pull both heads and get them pressure tested. Anyone ever rig up a pressure tester to attach to the heads at the fuel inlets, just thinking that would eliminate pulling the heads unnecessarily. How would they crack anyway......Sorry just rambling
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Old 11-13-2009, 09:35 PM
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no they are injector cups leaking. it's a big job if you're not familiar with these engines. it can be done on the truck. you need to remove the injectors and replace the cups...which can be very difficult especially if you don't have the right tools. there is a big tap that cuts threads into the cup then with another tool you have to pull and pry to get them out. rear injector are even more fun!
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Old 11-13-2009, 10:10 PM
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injector cups are a PITA
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Old 11-14-2009, 02:04 AM
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Boy you guys are up way past my bedtime. Thanks for responding.
i had a 95 7.3 that I replaced the inj. o-rings on. there was a little more
room to work on it with the cowl not being over the turbo.
Just wondering if you have a lead on tools. I guess I'll need injector o-rings,
probably glow sticks while in there, anything else you can think of?
Thank you again fellas. Jeff P.S Travis do you work for Inter.
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Old 11-14-2009, 01:02 PM
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the tools are expensive..this kit is supposed to be for the stainless cups which were in the later engines but it will work... yes i do work at an International dealer

ZTSE4683
Stainless Injector Sleeve Removal Tool $433.32
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Old 11-14-2009, 03:15 PM
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Ouch (for the tool), thats not even with the installer? You got a lead on parts, I'm in Wisconsin (between Milwaukee and Madison), the local Ford dealer in Watertown wants about 20 for the sleeve and 17 for the o-rings
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