03 6.0 Excursion - HPOP Replacement, Oil Leak... Help?! - Ford Powerstroke Diesel Forum
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Old 07-14-2012, 07:51 AM
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Lightbulb 03 6.0 Excursion - HPOP Replacement, Oil Leak... Help?!

After expending some effort to replace the HPOP over a series of evenings the last few weeks, I fired up the truck this morning.

Good news: The throttle response and overall performance of the truck feels great - I am attributing this mostly to the turbo reconditioning.

Bad news: Oil leak... It appears the oil is coming from the valley underneath the intake manifold but it is visibly dripping down the passenger side of the transmission. Accumulation after starting the engine is pretty consistent every time - about 1/2 -3/4 cup.

I used Ford RTV sealant on the back section of the HPOP cover per the Ford TSB but I am thinking it may have set before I was able to tighten up the bolts the next day (rain came in heavy right after application of the RTV).

Could the new HPOP be highlighting another weak gasket failure?

I am dreading tearing everything back down only to have another leak... any help is appreciated

Time for a drink while the beast cools...
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Old 07-14-2012, 07:56 AM
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Uhm....some have experienced a cracked cover after stc failure. Hope that didn't happen to you, did you inspect it well?

Sent from my SCH-I500
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Old 07-14-2012, 08:03 AM
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Quote:
Originally Posted by southend View Post
Uhm....some have experienced a cracked cover after stc failure. Hope that didn't happen to you, did you inspect it well?

Sent from my SCH-I500
Me too... I actually purchased a new HPOP cover (the one with the updated channel for the oil discharge tube). 2003 6.0 doesn't have the STC fitting but the cover looks solid and I will keep this in mind when looking.
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Old 07-14-2012, 11:29 AM
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I just finished tearing it back down to view the HPOP (the manifold is still on) but it looks like the oil was accumulating underneath the turbo pedestal between the HPOP and oil cooler.

My initial thoughts are the turbo drain tube was too far into the HPOP. Would it be recommended to pull the intake manifold and re-seat/RTV the HPOP cover?

Sidenote: The back bolts on the oil cooler appear tight but there is a few MM gap between the block and the backside of the oil cooler. Is this normal?
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Old 07-14-2012, 12:04 PM
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Wished I could help you better, I haven't had to do that yet. Reading through your post again, that rtv may have set up on you.

Sent from my SCH-I500
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Old 07-14-2012, 12:37 PM
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I helped a bud do his HPOP three times do to sealant issues. Bottom line, surgically clean surfaces seemed to be the key. I don't recall either on the gap question. Good time to put in the updated turbo supply and drain.
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Old 07-14-2012, 01:26 PM
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Thanks for the tips guys! Good to know!

I got the manifold and EGR cooler off and will be pulling the HPOP cover now. Will be diligent when cleaning the surfaces and reapply RTV.

Term3 - did you guys end up only using RTV in the back two corners? Any suggestions on what to use to clean surface?

Also, I have installed the updated turbo drain but am holding off on the supply line until I replace oil cooler (I have the older style cooler cover).

Hopefully I will get it put back together today...
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Old 07-14-2012, 08:30 PM
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Check your turbo drain line. After I replaced my hpop my drain line would leak I though the same thing that my hpop cover didn't seal. Put a new gasket on the drain line and now no more leak.
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Old 07-18-2012, 05:16 AM
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elm302 - good point, I checked and replaced the oring on the turbo drain line and re-sealed the HPOP on the second tear down. Truck started right up but ran terribly and was still leaking oil. After driving it a little bit Monday AM, it died and would not restart.

Had it towed to a stealership and am being told that IPR valve is shot and they can't diagnose oil leak until they replace IPR and start the truck.

Does this make sense? I replaced the HPOP cover with the newer design and it came with a new IPR. Any thoughts on if/where particles could be being sent through the brand new IPR screen? Could the reman. Ford HPOP be defective?

After all the effort, it is beyond frustrating having to throw 1k at the dealer to start their tally of other issues.
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Old 07-18-2012, 05:33 AM
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Quote:
Originally Posted by southend View Post
Uhm....some have experienced a cracked cover after stc failure. Hope that didn't happen to you, did you inspect it well?

Sent from my SCH-I500
I'm going through this at the moment. I had the darned snap to fit deal blow about a month ago and when that happened it cracked the rear cover. It doesn't leak a lot, but it does leak.

Luckily my warranty covers this and my dealer will fix it next week when we get back from RV'ing.

Good luck to the OP in getting his fixed.
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