08 Ford F250 6.4 Loss of power, Stalling , Crank no start

Roy Technician Salinas, California Posted   Latest   Edited  
Unsolved
Driveability
Loss Of Power
Stalling
Crank / No Start

Good morning DN,

Hello my name is Roy and I am new to DN . I am currently working on a F250 6.4L . The owner of the truck recently had the motor replaced due to major oil leaks . Since the motor has been replaced the customer has experienced loss of power, stalling while driving, and crank no starts . after the truck is warmed up (30 miles). I was able to duplicate the stalling with my scanner on it. While monitoring the fuel pressure at the rail I noticed the PSI from the rail was dropping from 5K psi to 2k psi during the stall. From what I have researched I found that based on the present symptoms the HP Fuel pump is the most probable . I skipped the low side pressure system tests and went straight to the fuel cooler and fuel filter mounted on the engine. I found metal shavings in the fuel filter but not enough to say I am fully convinced of HP pump failure. I was under the impression that there is to be not a single trace of metal in the system . That is the reason for this post. I am on the right track to suggest complete fuel system overhaul?. I also forgot to mention that there is no codes stored . 

Thank you . 

any and all reply's are appreciated.

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Mike Instructor
Fresno, California
Mike Default
 

Were both fuel filters replaced when the engine replaced? A better place to take the fuel sample is at the cylinder #1 and cylinder #2 fuel transfer tubes on the rail at the injectors. Yes, it's a hassle, but what isn't on this engine?

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Roy Technician
Salinas, California
Roy Default
 

I am not sure. I have little to no info on this tuck. the previous work invoices are very vague. I will suggest to remove and inspect the tubes. Thank you for the reply.

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Chris Technical Support Specialist
Commack, New York
Chris Default
   

Don't forget to jack up the rear of the truck to help the debris move to the front of the rail :) If any debris are found you will need to flush the heads PRIOR to replacing the injectors as well as rails, hp pump supply check valve, supply tube, fuel cooler, etc. HP lines are one time use.

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Roy Technician
Salinas, California
Roy Default
 

I will do what you suggested . I found a TSB pertaining to the cylinder head flushing procedure. Are the special tools absolutely needed for the flushing of the cylinder heads? one is a plug and the other is just a threaded spout it looks like. Thank you for the reply

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Chris Technical Support Specialist
Commack, New York
Chris Default
 

The same banjo fitting from the 6.0 L is the same size as the port in the head. I would normally do these cab off. I would disconnect the Pressure outlet of the rail mounted fuel pump and connect a hose to a fuel injector flush banjo adapter. I would pulse the fuel pump in short bursts to flush the head. I would flush maybe a gallon per side. You need a fitting for where the return line is at…

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Roy Technician
Salinas, California
Roy Default
 

Thank you . Very useful information. I will apply this info to this truck if they decide to do the work.

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Jim Owner
Philadelphia, Pennsylvania
Jim Default
 

Were the original injectors used or were the new ones registered to the PCM?

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Mike Instructor
Fresno, California
Mike Default
 

The injectors on the 6.4L do not require this. Only on the 6.7L Powerstroke

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Roy Technician
Salinas, California
Roy Default
 

Good to know. Thank you for the reply.

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Roy Technician
Salinas, California
Roy Default
   

I did not find any codes to suggest they were not otherwise. Thank you for the reply

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Mike Instructor
Fresno, California
Mike Default
 

Roy, where do you work? I have some shop connections in Salinas.

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Roy Technician
Salinas, California
Roy Default
   

Hello mike, Thank you for the reply. I work for myself. I do work out of Prundale.

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Albin Diagnostician
Leavenworth, Washington
Albin Default
 

I feel your pain Roy. Anything on these engines is hard to work on. If you have found any metal in the fuel system, your customer is in for another quite costly adventure. As the others have said, check in the rails too. These engine have a very troublesome high pressure fuel pump, and (shudder) any time an engine is changed, the pump should be changed too. At this point, it matters not if the…

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Roy Technician
Salinas, California
Roy Default
 

Hello Albin, Thank you for the reply. I agree with you totally . Major pain. What a unfortunate turn of events for this customer. I hate to deliver the bad news . This "deal" of a truck has turned into a money pit. based on the hard facts. Complete fuel system over haul is needed.

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Albin Diagnostician
Leavenworth, Washington
Albin Default
 

Well Roy, this engine is a money pit no matter how you stack it. :)

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Adam Technician
Olympia, Washington
Adam Default
 

Roy if it’s a complete reman from Ford then I would concentrate on the pcv and vcv on high psi pump. The plants that are building these motors are not correctly seating the connectors that go to high pump. We have handful that we had to go in and replace the gasket cover which has the connectors integrated with it. Normally is the pcv connector not seated. You can literally touch it and will…

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Dale Inspector
Dallas, Texas
Dale Default
 

I can't speak to the pressure, but clogged cats would have been the first thing I checked.

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Roy Technician
Salinas, California
Roy Default
 

I forgot to mention I had previously inspected the complete exhaust system due to back pressure and dpf codes . Thank you for the advice

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