6.0 Liter Ford Powerstroke - High Pressure Oil Pump & Revised STC Fitting Part 1

[@overpinned6171]

RIP Rusty Guys, Many of us knew Srmastertech through his KZbin videos and also learned how to work on our trucks because of him. I'm sure at one point or another, he's saved you or a buddy from a trip to the dealer a time or two. Few knew of his battle with cancer and it is with a very heavy heart that I say that Srmastertech aka Rusty Bunn lost his battle with cancer on January 28th, 2016

[@ldtexas1648]

I was just about to comment when I saw this one. I'm sorry to here of his passing. Also of Diesel tech Ron. They really helped me out a lot. Thank you for letting us know.

[@seannot-telling9806]

@@ldtexas1648 We lost two very caring guys in a short time of each other. They will live on through the videos and info they gave to use. Rusty and Ron rest well you are missed.

[@bradgrozdanich7416]

Between you and Diesel Tech Ron, you have the best content on the internet. I recently bought a 6.0 powerstroke and really need it to last for as long as possible to try to get a business up and running due to health issues lack of funds. Your sharing of your expertise is priceless for me and I just want to thank you, it means much more than I can ever explain.

[@RTFLDGR]

Can't tell you all how much I appreciate these videos. Thank you for sharing. This is the internet & gearhead community at it's best.

[@wayland1268]

I have worked on Mack trucks and heavy equipment for over twenty years but this HPOP has kicked my butt! I have had more trouble from the heat shield than anything! I am just to big for these tight ass fits!!!! Thanks to U an your video I can see light at the end of the tunnel! Thanks for your help and keep on keepin on!!!

[@jason2sperry]

I have a 05 excursion 6.0 I would like to say thank you for people like you who do videos like this. This is great for all because whether I do the job myself or have someone do it for me at least I have a good idea about the job thank you again

[@Codyismyname.]

Best hpop replacement video ever.

[@denb4626]

Awesome short cut and major time saving for money for customers to save too

[@theresacruz1742]

One of the best hipop system diag videos out there,to be able to diag leakage points based on low psi numbers can only be done with a lot of experience with the system

[@anthonyhaskins3875]

i want to congratulate you on your video in all aspects. i watch alot of videos of diferent kinds and your instructional was the best great step by step. im a 52 yr old mechanic so great job

[@oldguitarhack]

About to replace the STC fitting tomorrow while in for an EGR cooler and oil cooler repair. Great info. One of the best videos I've seen!

[@alely1031]

Phenomenal detail. Outstanding diagnostics as this is precisely what happened to my F350 6.0 liter unit.

[@albertstandish1439]

Very helpful I am reinstalling my HPOP and it was good instructions on the s t c fitting that I needed thank you.

[@ademgblue]

Badass , straight to the point , no bullcrap

[@Komelika]

Man, you are going to save me a lot of money! I appreciate the information. You remove the mystery behind it all. Now I just need to get a torque wrench and get busy!

[@dd14881]

Thank you so much for your time and knowledge it helped me out s much and saved me 700$$$ to 800$$$ in labor cost keep on making these videos they help out and save a lot of money for all of us who do it on our own...

[@proutya]

Great work on these videos... Really appreciate the time you put into them.

[@Kanesgarage]

Nice job Rusty, as usual! I like it when you narrate throughout the video like in this one, it works better than music in my opinion!

[@LHG86]

Awesome video. This is definitely going to help me when I replace my STC fitting. Thanks.

[@srmastertech]

@dmageeny Great to hear you got it figured out and running again!

[@dmageeny]

@srmastertech so I'll take that as a no on the loctite. I appreciate you taking the time to answer my rookie questions! David

[@srmastertech]

@06dirtyblack Your very welcome, it's my pleasure to help out. I've been fortunate enough to have helped all around the world, so I'll put a pin up for NY! I completely understand about keeping business running when you down. I always keep that in mind with all my customers. If you need anything, just ask!

[@srmastertech]

@Komelika Good luck with your repair and I hope it turns out great! I do accept tips, lol!

[@dmageeny]

@srmastertech I'm not at my truck, but I just bought the STC HPOP fitting update kit from the dealership. They could only tell me it was built in 4/18/04. I will have to take a look in the engine when I get home. You would think the ford dealership would know more about their product. David

[@srmastertech]

@06dirtyblack The blue charge air hose for turbo outlet does get small perforations that allow it to look like an oil leak. You can replace the hose and most dealers keep those in stock.

[@dmageeny]

@srmastertech That's just it, I don't have an STC fitting. It's an early model 04. The rear cover looks good and so does everything else. I just saw the one gasket broke and oil on the heat shield just outside the crack so I'm replacing the gasket tomorrow. I'll let you know how it works out.

[@srmastertech]

@dmageeny I believe you mean you have the first production of the 6.0lit. Navastar's wonderful design! Be sure you leak is from the gasket. I have seen some where the STC fitting damages the rear engine cover and cracks it. When it leaks, it looks like the pump cover. I completely understand your frustrations, I deal with it everyday!

[@srmastertech]

@everynameistaken567 Great question and I accept criticizing! There's is always a chance a bolt could fall out of the cover during removal. Under the rear cover, where the pump mounts, is a cavity that if the bolt fell out, it would land in the cavity and not fall deep into the engine. the rear half is open, but the rear bolt can be removed. You just have to go slow and don't rush, the bolts will stay steady in place.

[@andresmejia7741]

This is a bad ass video! Very very proffessional .Thanks brother!

[@srmastertech]

@Thump863 There is now way to torque the pump cover with the intake and cooler in place. For those bolts, tighten by feel. AE is a great product for the price. The best and only way to test the High pressure oil system is by air testing with the special service tools.

[@rob77373]

Yes, it would come out some what easily. I'm no mechanic but I know my way around this engine fairly well and I wouldn't recommend removing or attempting to remove the egr cooler with the HPOP uninstalled. I say this because even if you were to drain down the coolant from the engine there will still be coolant in the cooler and there is a pretty good chance that it will be spilled during removal. Coolant that has been spilled can make its way into the crank case causing more work to remove it.

[@srmastertech]

@audiohighway I use factory equiptment, it is Ford's IDS - Integrated Diagnostic System. A great tool I will not work without!

[@James-Orr]

Thanks again for another helpful video!

[@srmastertech]

@wayland1268 Thanks for the great comment! I'm glad I was able to help!!!!

[@srmastertech]

@dmageeny Actually, the early production does have the STC fitting, but not the same design. You design mounts on to the top of the pump. If you see the gakset pushed out, your on the right track. Don't have too much fun!

[@srmastertech]

@Goodwrench496 The 6.4 fuel injection is very different. The pump in the engine is now a fuel pump, not oil pump. It can produce up to 25K psi to supply the injectors. It is controlled by a pressure and volume valve mounted on the pump.

[@srmastertech]

@dmageeny That can be considered a trick question! An 04 Powerstroke came out as a early production model, and late production model. Simple was of telling is to look at the passenger side valve cover. You will see a finned aluminum box, thats the glow plug relay. If it is mounted horizontally, with the connectors at the bottom, its and early model. If it's mounted vertically with the connectors toward the rear of the engine & an ICP sensor next to it, it's a late production, Late model has STC

[@srmastertech]

@dmageeny You could use loctite, but the bolts do not torque down that much. I do see the turbo bolts off all the time. When you get the Ford turbo kit, it comes with new bolts. On your model, there are also spacers that go on under the turbo mounting bolts. I wouldn't use loctite on those, they can get stuck easily on their own.

[@srmastertech]

@808hawaiianfire You are building some pressure, but not a lot. At this point, by the pressure your reading, I would say yes, you leak is most likely from the d-ring seals. But these are not on the injector. The d-rings are part of the dummy plug on the high pressure oil rail. The Ford part number is W302908. There is one on each oil rail.

[@dmageeny]

@srmastertech My original problem was the check engine light coming on at idle and the oil pressure gage dropping to zero, but when I hit the gas everything would be normal. It runs great, but has a hard time starting. From the forums I figured it was the HPOP. I tore everything down and noticed a potential gasket leak so, but everything else looked great with the HPOP. I put everything back together, got her started and went on down the road. Same problem came back.

[@DTerrordome]

Very informative thanks a bunch

[@srmastertech]

@ladsjohn The cooling system, including the EGR cooler does not need to be drained. When removing the inlet clamp, no coolant flows through that clamp.

[@srmastertech]

@wayland1268 Replacing the injector seals is a bit overkill and nothing to do with the high pressure oil system. I would recommend replacing the STC fitting while your there. The up tubes don't have many problems. The only time I replace them is with a cylinder head.

[@Rengo11]

update figured it out it was exhaust clamp not clamped all the way so got it fixed

[@srmastertech]

@2765r On this video, I just installed the revised STC fitting. The pump was working normally and did not need to be replaced. A lot of pump have been replaced with people thinking it was the pump, when actually the fitting just leaks and fails.

[@srmastertech]

@Goodwrench496 On the 6.9lit, the fuel system relies on a minimum of 45 psi and the high press oil system opens the injector to fire when the injector is electrically commanded on. The 6.4lit is just the opposite. The 6.4 has a high pressure fuel pump to increase the fuel pressure up to 25,000 psi. better atomization of the fuel is what makes it quieter than the 6.0lit. The new 6.7lit also using high pressure fuel and a better delivery system with the fuel outside the crankcase.

[@srmastertech]

@fordpowerstroke2012 The simplest answer is yes, in a Ford catalog, it does show as a fuel injection pump, even if it doesn't pump fuel.

[@dmageeny]

@dmageeny Turned out to be the non servicable plug gone on the HPOP pump. I had it tapped and plugged and I put the pump back in and put everything back together. I forgot to put the clamp back on the EGR Cooler exhaust right next to the HPOP pump cover. That is why it didn't start! I was able to get my hand down in there and put it back on. It started right away. I drove a mile and a half easy down the road. Stopped for a minute and took back off to drive it hard to get the bugs out.

[@srmastertech]

@prsar6 I use Ford's system for diagnosis. It is a software package call IDS (Integrated Diagnostic System). That is the software and hardware that is the VCM (Vehicle Communication Module). There is also another hardware component that is also available, but not always required. This software rung on just about any windows PC using XP pro or Windows 7 32 bit. It is a great tool and I wouldn't use anything else for diagnosing a Ford!

[@onaciam]

where do i get this software from

[@wayland1268]

Man U make it look easy! The same thing happened to my truck died going down the road! My truck has 78 pounds of pressure. I am totally replacing everything while i have it down. HP oil rail o-rings, injector o-rings and copper washers, HP oil pump and from what i see here the STC fitting too. Should I replace the revised HP span tubes?

[@srmastertech]

@rdp2370 The first thing you will notice, is that the fitting will be very loose, almost wobble to just about fall out. On the male end, you will see that there is a polished ring, on the female fitting, there is an oring and a nylon ring that most of the time is not even there anymore. If the fitting falls out without having to remove it with the special tool, the fitting is completely worn out.

[@kurmazz12]

About a month ago I replaced the rear cover of a 6.0 because it was broken and leaking oil in spot where the stc rubs on. At the time I wasn't aware that this was a common issue. Starting today , the truck cranks and won't start. I believe you just gave me the answer to my question, do they break the cover often?

[@srmastertech]

@dmageeny That's correct David, no loctite on the turbo bolts. You can on the turbo pedestal. Your very welcome! Rusty

[@javinsdad]

I have a motoralldata subscription and it says to Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash. I am installing a new HPOP and i m wondering if this is necessary to do? Also on the late build, is the fitting for the oil rail that goes into the heads the same? You and your videos are lifesavers!!!!!!!!!!

[@dmageeny]

Respond to this video... Stepped on the gas and nothing. Hesitated, all check engine lights on and died! No fluids on the ground, no terrible noises, no steam coming out, no black or white smoke out of the exhaust. I'm at a loss. I guess I'm going to tear it down again and hope for something obvious to pop up. David

[@srmastertech]

@Goodwrench496 In the simplest terms, it take high pressure oil to physically fire the fuel injector.

[@srmastertech]

@Thump863 This repair should take about 7 hours. A dealer repair with parts will run around $100 is they use new coolant, intake gaskets and a turbo seal kit.

[@srmastertech]

@PWRSTR0KER2008 Thanks, I really appreciate it! I feel better doing the narration, I just have to write out what I want to say. Now it feels like a script, lol!

[@Cableguy1225]

I purchased an 04 F350 6.0 Dsl. Before I purchased it I read all the blogs, saw a bunch of videos on bullet proofs, egr deletes, head studs, etc. The truck was worked on a few times by the dealer and has had the head gaskets, water pump and a few other things done in the last 2 yrs. My question is should I keep feeling like I should baby this truck, will it need the upgrades such as head studs, upgraded head gaskets, deleted egr or updated egr, etc.? What am I looking at here? Thanks.

[@dmageeny]

@srmastertech My seal/gasket on the back right corner of the HPOP gave way and was leaking. Just replaced the gasket and away we go!

[@rdp2370]

Rusty when first pulled the old STC fitting out you said its completely wore out. What were you looking at so I can I go back to and revisit that part.

[@salvanicca]

Great video! I went ahead and did this same procedure to change an stc fitting in my 04 6.0L well come to find out i pull the pump cover and i dont see an STC fitting in there.. my truck will crank but not start.. checked all sensors and came back good.. any help please?

[@johnpage1001]

@ Srmastertech, at about 4:40, why do you remove ear coolant clamp? I won't see you remove the cooler itself, so what is the purpose? am I missing something? I am at this exact step in the procedure and just need to know why you did that please sir. thanks, John

[@eliasfaithjoseph1]

i have 2004 2500 6.0 , i started truck up let it warm up , took kids to school , check gauge light came on , my oil pressure gauge went don to lowest and came back up , and check gauge light shut off , it did this 4 times and it stopped doing it ,checked oil level its good , and the truck has been leaking oil , help thanks .

[@dmageeny]

@srmastertech It was sheered off and bunched up. I'm going to replace it tomorrow. If I can get all those hard to get to screws back on I will get r running. Is it ok to put that lock tight stuff on the screws when putting them back in? When I tore it down there were two out of the four screws out on the turbo pedestal and the other two loose. David

[@kdmq]

What sort of pressures have you seen from failed HPOPs in the 03s and 04s?

[@topadman12]

Today I proceeded to pass a semi in the left lane so I gave the 6.0 a little fuel and it started dying on me,, So I coasted to the side of the road and waited 15mins. It then started again and made it another 1/4 mile and it lost power to a near stall. Waited another 15 mins and made it another 1/4 mile before it did the same thing again. STC fitting maybe? Dummy plugs? Does this sound like a small but not complete lost of high pressure. Would need your input on this my friend if you please!

[@cesarjesusponce4993]

i do have the same problem do you fixed and how much do you spend????

[@cesarjesusponce4993]

i have the same problem do you fixed and how much do spend???

[@fordpowerstroke2012]

@srmastertech lol thanks ya it seemed weird to me how everything was identical except for the name :s thanks for the reply though! good ol 6.0.....when they run :p Love them!

[@TheMolacho1]

You are the bomb!!!

[@fordpowerstroke2012]

@mannasteve thanks i got someone in at ford that can get me the parts at cost so veryyy cheap but thanks for the info ill still check it out!

[@srmastertech]

@proutya Thanks for the comment! I appreciate your support!

[@charlesbako3829]

On a 60 2004 Ford will it make the high pressure fuel pump will it oil pump I mean On a Ford 2004 60 6 l where the high pressure pump makes the oil pressure gauge just dropped to nothing when you are stopped it works fine going

[@Woody85225]

Yes what do you have to do to replace the cover? any info will be helpful .

[@otisguide]

I have a high pressure oil leak. It is probably this STC fitting. If my oil pump is covered by my extended warranty would it be easier and smarter to just replace the whole pump?

[@srmastertech]

@studbolt88 Many things can cause those symptoms. Do you have any DTC's? I would look towards a sticking EGR valve, ICP pressure? Pretty tough to guess on the internet!

[@pbalerig]

What is the latest part number? When I did mine over the summer I did not have the alignment tool and I think I could be leaking a little... not sure...

[@musicalpriest1]

I have followed your videos to the T in replacing my EGR cooler and oil cooler. I was intending to replace the STC fitting as well. However on my 2005 Excursion 6.0L The pump housing is different. And the whole assembly under the cover is different and I see no STC fitting as indicated in your vid. Any info? Are there multiple versions of the HPOP? I am confident I am looking at the right thing. No doubt, it just is different from yours. Whats up? No STC on 05 excursion?

[@charlesbako3829]

How many miles will a 60 high pressure pump last

[@jtnoodle]

it appears that the EGR cooler would come out somewhat easily with the HPOP removed. True?

[@fordpowerstroke2012]

IS the HPOP on a 6.0 superduty also called the fuel injection pump? im trying to find the cost of the hpop on the ford website but i cant find it only found a fuel injection pump which looks identical to the HPOP just curious thanks.

[@ladsjohn]

Does the EGR cooler need to be drained before removing the inlet clamp?

[@audiohighway]

Fantastic!!! What software are you using to diagnose?

[@blamewho3149]

what was that tool put into the hole of the oil pump cover so it could be taken off ?

[@tomhadoulias7571]

Just curious what your procedure is for removing the heat shield bolts on the back of the HPOP. I can feel them but at a later age in life it's pretty tough to get back there and remove them. Intake is off, vehicle is a 2006 PSD F250. Thanks! Any help is greatly appreciated.

[@joeldaniel1808]

6L power stroke, I installed oil cooler and egr bypass. I also removed hpop to install fitting and it already had the upgraded fitting so new O-rings and reinstalled everything. hit the starter and it spins like it doesn't have any compression? What is going on?

[@peteleavitt5703]

So if it's got 300 PSI thereabouts what did you say the problem was

[@srmastertech]

@pbalerig I Dont remember it on hand, but I post it tomorrow!

[@rhfd324]

Just pulled my HPOP cover to replace stc for a crank no start and noticed that the rear cover is cracked. How bad is it to replace???

[@Mrdubomb]

Is it possible to rebuild these hpops?

[@walkortalk]

I have a 2003 Excursion with the 6.0 and was told the HPOP was bad and need replaced. Can it be done without removing the intake?

[@karinaarevalo_]

Need help ...2003 Ford f 250 6.0 diesel was working good suddenly it died it wont start again. Fuel pressure gauge is low doesn't go up. The problem could be the oil pressure pump Please let me know to change it Thank you.

[@studbolt88]

Would this cause a stumble, surge and die type of issue?

[@everynameistaken567]

when you take off the pump cover with the bolts still in it, wouldn't it be easy to accidentally drop them down into the pump? I'm not criticizing you, just asking.

[@dmageeny]

Respond to this video... My batteries are very old and don't hold a charge long at all. Can this check engine light on low oil pressure and hard starting be a battery issue? David

[@alejandro19272]

very helpfull video thanks :>}

[@meadowskaty6]

What kind of torque wrench you using? Also can I buy that software your using of so where.

[@Idgafmichael]

If I pump air through the STC, is it supposed to come out of a hole located in the front of the pump behind the gear?

[@thomasmarquez6790]

Do I need to remove the intake on a 2003 6.0l to get the pump cover off??

[@jtnoodle]

I thought so. Thanks.

[@dmageeny]

@srmastertech I have the vertical with connectors towards the rear, but still have the early HPOP. It turns out I have a break in the gasket in the back right corner. Who was the rocket scientist that decided to attach the heat shield to the HPOP and do it with the bolt facing the rear where we cannot get to it?

[@jimmyaustin375]

Ford has a fleet of rocket scientist working for them!!

[@kevingomes201]

i have a 2003 ford e 450 with a 7.3 litter diesel my hpop is leaking and i got a rebuild kit rite from International to rebuild how can i get a video to show how to rebuild the pump can u help me ? please