Ford 6.0L Powerstroke Premature Injector O-Ring Failure

Ford 6.0l Power Stroke Tech Bulletin – Premature Injector O-Ring Failure

 

This bulletin addresses common issues encountered with the premature failure of the G2.8 injector oil seal or sometimes called the “D-Ring”

 

Problem / Complaint:

• Engine has a “Hard Start” or “No Start”
• Engine stalls when hot, won’t restart

 

Probable Causes:

Most likely causes are bad injector oil seals “D-ring” (Check Figure 1 Below)

FIGURE 1

 

Causes of Injector D-ring Erosion:

Leakage from hair line fractures in the Ball Tube

• Fractures porpagate from the damage on the end of the Ball Tube (Check Figure 2)
• Fractures are typically visible (with magnification) on the inside diameter of the Ball Tube
• High pressure oil blast through the crack and erodes the D-ring from the inside 

FIGURE 2

 

Leakage between the Ball Tube and Injector D-ring

 

• Installation damage to the D-ring from reuse  of damage Ball Tubes.
• Poor D-ring to the Ball Tube Seal from reuse of worn Ball Tube (Check Figure 3)

FIGURE 3

 

Leaking Ball Tube O-Ring

 

• Ball Tube O-ring flattens and hardens with age, allowing high pressure oil to escape past the Ball Tube O-ring, and blasting the top of the injector D-ring. (Check Figure 4)

FIGURE 4

 

Leaking between Ball Tube and Injector D-ring

• Installation damage to D-ring from misaligned Ball Tubes (Check Figure 5)

FIGURE 5

 

Recommendations:

• Replace Ball Tube and O-ring (F60ORBT-8) when installing injectors
• Use clean engine oil to lube Ball Tubes prior to installation
• Ensure Ball Tubes are aligned properly when installing injectors.

 

Torque Specification:

• Ball tube Retaining Nut – 100 lb-ft (136 Nm)
• Injector Hold Down Screw – 24 to 26 lb-ft (33Nm)

 

Preventative Maintenance Schedule:

• Replace Engine Oil (15 Qts.) – 5,000-7,500 miles
• Replace Fuel Filters – 10,000-15,000 miles