My 08 F350 6.4 needs a new fuel system !

[me2]

My 08 F350 KR is sitting at the local Ford dealer. I bought it used with 80K miles. I now has 96,500 miles on it. The engine is under warranty until 100K.

I took it in because it has smoked out the street a few times. It
doesn't do it often, but every now and then it does. Fortunately it
did it for the mechanic at the dealer.

It was also gutless and a pig on fuel. It was also at the dealer for an EGR problem (covered under warranty) about a month ago.

They pulled the secondary fuel filter after the high pressure pump and
found metal shavings. The high pressure fuel pump is shot. The
injectors are also now all shot.

At this point I have a decision to make.

I can pay them 12 hours of labour (at over $100 per hour) to pull the cab
and pull the high pressure fuel pump. When they pull the high
pressure pump, they take it apart and check for rust. If there is
rust, Ford claims there was water in the fuel at some point and denies
all warranty. If they don't find any rust in the pump, they will fix
everything.

It costs over $10K to replace the high pressure pump and all the injectors.

I can no longer drive the truck as it is because if an injector
sticks, it will melt a piston in the engine. I'm probably lucky it
hasn't already.

This dealer has 3 6.4L diesel trucks in their shop right now with the
same problem. One blew the engine. One had no rust. One had rust.
1 in 3 of these trucks is going to get warranty, the other two
truck owners are going to get big bills.

[gavan]

If you are going to swap your Cummins into it anyways, cut your losses and do the swap now. Sell the engine as a core. Move on with life.

a 66% chance of paying 12k to have a truck fixed that you are going to put another motor into anyways? Especially since you bought it used, who knows what kind of crap fuel the PO used in the truck.

Or, find another dealer and get another opinion.

[me2]

Originally Posted by gavan

If you are going to swap your Cummins into it anyways, cut your losses and do the swap now. Sell the engine as a core. Move on with life.

Yep. Luckily I have most of the pieces for the swap ready to go. Now I have to get on it double time.

The rest of the engine is fine. Its worth way more than a core.

[RSwenson]

Had this happen last month.
HPP was replaced under warranty at 92K.

Have the dealer check TSB 11-4-22, this is quite common.
Its not always a water in the fuel issue.

[Rockcrawler_101]

6.4l suck. My work truck has had its cab off 5 times and had two radiators put in it with only 50k on it!

[roceatr]

I have an 08 F-250 6.4 with only 20,000 miles. Truck was in for an oil leak at the pan. Picked it up and drove it 1 mile and it died. Towed it back to dealer. It was the high pressure pump. They said it came apart and put metal shavings into everything. Had to replace injectors and pump and flush the whole system. I have not been home for a month so have not driven the truck yet. But pissed that it has had 2 oil leaks and now this. Bought truck new so to say the least i'm dissapointed in Ford.
All repairs are under warrenty but still

[#rawkon]

Sounds like the 6.4 is trying to catch up to the 6.0. maybe ford needs to hust go back to the 7.3 adn forget all the rest of these shit motors.

[me2]

Originally Posted by RSwenson

Had this happen last month.
HPP was replaced under warranty at 92K.

Have the dealer check TSB 11-4-22, this is quite common.
Its not always a water in the fuel issue.

I agree that its not always a WIF issue.

But they need to pull the cab to get the pump out to find out and that is about a $1500 bill. How did they handle that part of your situation ?

I don't want to spend $1500 to have them pull the cab and HPFP and then find out there is no warranty coverage.

Are you saying that I should roll the dice on pulling the cab ?

I agree with all the other statements being made here about the 6.4

And one other thing... the 6.4 is a total pig on fuel. I've never seen a truck use so much fuel. It uses more fuel to pull a small UHaul trailer than my old truck did pulling a 35 foot 5th wheel trailer. I kid you not.

[RSwenson]

They plugged in a laptop, found I had a HPP problem.
Checked the warranty situation and did everything under warranty.
there were two other trucks in that shop with the same problem.

[me2]

One of the reasons I'm so pissed about this situation is that the timing to do the swap is terrible. For one thing, I don't have a welder right now and won't for another 2 weeks. And I am just sorting out the transmission setup.

Just my luck that the stupid POS 6.4 couldn't make it another month before it decides to implode.

[46/71 Hybrid]

Any thoughts of pulling the cab yourself to check the pump? If it's good to go, have them do it. If not, it'll be easier to swap your other engine with the cab off anyway.

[gavan]

They will probably have it for a month anyways. Big warranty repairs do not always get top billing.

[roceatr]

I have to agree with me2, My 6.4 is a pig on fuel as well. I get around 7 to 9 miles to the gallon towing a car trailer with my toyota truggy and about the same towing my 27 ft enclosed snowmobile trailer. However I only get about 13 mpg to at best 14 mpg empty.
Truck is lifted 6" and has 37 tires. But that is only about 2 inches bigger than stock. I don't drive 55mph but I don't drive at 80 mph either.

[1slosvt]

i have an 08 f250 with egr,dpf and cat deleted plus a few other parts and a solid tune with 130k 30 of that with mods with almost no issues ever. i also have an 08 f350 stock with 150k on it again with almost no issues ever. i guess its just bad luck

[me2]

I had the dealer pull 2 injectors. They found them to be perfectly clean. Given that, the tech thought the chances of finding rust in the HPFP were low.

I instructed them to pull the HPFP.

I'll know how it turns out tomorrow.

The dealer said Ford would not participate in fixing the fuel system if I did any work on it.

[me2]

Originally Posted by roceatr

I have to agree with me2, My 6.4 is a pig on fuel as well. I get around 7 to 9 miles to the gallon towing a car trailer with my toyota truggy and about the same towing my 27 ft enclosed snowmobile trailer. However I only get about 13 mpg to at best 14 mpg empty.
Truck is lifted 6" and has 37 tires. But that is only about 2 inches bigger than stock. I don't drive 55mph but I don't drive at 80 mph either.

My 08 truck is stock, with Ford 20" wheels and A/T 275/65R20 tires in the back and A/Ss in the front. I drive 65 MPH and I get similar fuel economy. I got under 10 MPG pulling a little UHaul trailer. I was too disgusted to work out the exact numbers.

My '99 is an F250 2WD with the same tires and a 5.9 CR with the timing advanced and ZF6. It gets an honest 22MPG empty, round trip in good conditions and between 10 and 11 MPG pulling a big 5th wheel trailer.

Similar trucks, same axle ratios, same OD ratios, same tires. The 08 sits about 2" taller and weighs about 1000 pounds more than the '99 and burns just about 50% more fuel, city or highway. And the '99 is way peppier.

I swapped the 5.9CR in it 6 years ago and never even really finished it properly. It just runs and runs. I think I've changed the fuel filters once. The oil change interval is like 15,000 miles and I use an $8 Walmart Fram oil filter.

The tech at my Ford dealer says if I want the 6.4 to live I need to use synthetic and change oil every 5,000 miles. The oil filter is $30 and the fuel filter is over $75.

I'm sure the 6.4 can be improved over stock, but I can't wait to get the Cummins 6.7 in my truck.

[me2]

roceatr: I wonder if our fuel economy will go up now that our fuel systems are fixed ?

Not that I am going to find out. My truck has about 2500 miles of warranty left. I hope to have the engine pulled before it expires.

[cguth]

take the truck home. somehow get a hole in the oil pan from debris in the road. smoke the engine. call insurance company.

[DT75FLH]

My job 1 08 6.4 got around 12-13 mpg empty...would get 10 towing a cartrailer....

then it went down to 11 empty as it broke in,,,

final straw was 10.5 with the wife driving EMPTY at 70 mph...after 3 radiators/1 steering box/1dpf (that I had to take in 3X before they would fix it)

ford told me to pound sand...they would not look at MILEAGE claims..even though the truck was stock and I logged every tank fill from 10 miles up to 51k miles....

went to dodge and bought a 2010 6.7 with 0.9% finacing and 15 mpg empty...
after 3 fords (one 2002 7.3 with zero issues) I will not buy another one.

[1tonscout]

Originally Posted by cguth

take the truck home. somehow get a hole in the oil pan from debris in the road. smoke the engine. call insurance company.

^^You're an idiot. Insurance fraud, the dealer has this documented at this point. A blown motor would more than likely get replaced with a short block, which doesnt include the fuel system. If you've ever looked underneath one of these trucks damage from "road debris" would be hard to come by. And these trucks shut down with lack of oil pressure to protect catastrophic engine failure.

To the op, as a ford diesel tech I've replaced quite a few pumps never seen one get kicked for rust. Hope the dealer you have yours at right now has the gasket for the pump. They are on national back order, i've got a truck right now waitin for a pump but cant get the gasket. Good luck

[me2]

Originally Posted by 1tonscout

^To the op, as a ford diesel tech I've replaced quite a few pumps never seen one get kicked for rust. Hope the dealer you have yours at right now has the gasket for the pump. They are on national back order, i've got a truck right now waitin for a pump but cant get the gasket.

FFFAAAAWWWWKKKKK ! If it ain't one thing, its another.

Thanks for the detailed reply.

Why are these pumps failing ?

[brooks294x4]

if this problem is happeneing to alot of ford 6.4s and it does seem to be a common problem. i would tell that that you have done your research, its not a fuel problem, and refuse to pay for something like that still under warranty coverage.

i work on duramax's and bad fuel/water in tank/filled with gasoline doesnt happen much. and when it doesn ive never had to put an injection pump in one. a couple injectors for clogging with dirt sure but i think ford feeding some people a line of shit on that situation.

[roceatr]

me2: I will let you know if has improved when I get home. I'm in Nigeria until the end of the month. Should be able to report back the first week in april. But I sure hope it improves.
I can't get rid of the DPF as I live in CA. And have to deal with all the smog crap. Sure my truck is cleaner out the tail pipe but I have to burn twice as much fuel for the same distance traveled??? How does that help anything or make cleaner air???

[Bustin Loose]

I don't trust dealerships as far as I can throw one. Just another FANTASTIC reason why I bought my very roughly used MDT with a still working 7.3. Good luck on the engine swap.

[pennsylvaniaboy]

Originally Posted by brooks294x4

if this problem is happeneing to alot of ford 6.4s and it does seem to be a common problem. i would tell that that you have done your research, its not a fuel problem, and refuse to pay for something like that still under warranty coverage.

i work on duramax's and bad fuel/water in tank/filled with gasoline doesnt happen much. and when it doesn ive never had to put an injection pump in one. a couple injectors for clogging with dirt sure but i think ford feeding some people a line of shit on that situation.

HAHAHA I always laugh when people buy a new truck, then complain abt getting raped by the stealership. You could not pay me to buy a new truck. They continually play games, find things that arent broken, then do not stand behind their vehicles.

If that many trucks have problems they should do a recall. You shuold not pay 1 penny for a new vehicles issue till the warranty runs out......ever.