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Discussion Starter · #1 · (Edited)
2005 F-250 Crew Cab 4x4 6.0 Powerstroke
FASS Fuel System 150gph
SCT Livewire TS
Everything Else Is Stock


Last week I was traveling from Mattawan, MI to Indianapolis, IN. I was just south of Peru, IN when my truck just died going down the highway. It had done this before about 3 months prior and I thought I might have just not have the ignition turned all the way (LOL). So I stopped on the side of the road and done what 99% of people would do. I checked all my gauges (STC Livewire TS, Pillar Mounted, and the stock ones) Everything seemed to be in its normal area. Coolant was 201, Oil was 209. I shut the key off and waited a few seconds and tried to start it. It cranked but would not fire. I got out and opened the hood and didn't see anything leaking, so I walked to the passenger side to grab my safety triangles when I seen this puddle of oil. I proceeded to put the triangles out and think of where it could be coming from. (I am a large and in charge man who doesn't fit well under my running boards). After calling a tow truck I was searching google like a mad man trying to find some answers but was coming up short. My insurance company would only tow me to the closest FORD STEALERSHIP which was in Kokomo, IN. I got there around 1715 and the shop closes at 1700. I spent the night searching the net trying to find out where this oil could be coming from. I started checking everything I could think of under the hood. Pulled the dipstick and it was about a qt low, popped the coolant cab and seen something floating in the reservoir. After a closer look it was fuel I was seeing. I called a buddy back home (500 miles) and got him on his way to load up my truck and bring me home.

Well today I drained the coolant and this is what it looks like.

Drained into a bucket


Drained into a bucket 2


Sample skimmed from bucket


Sample skimmed from bucket 2


Sample skimmed from bucket 3


Now if this was not enough. I was looking to see where the oil came from, only to find the rear engine cover to be broke and pushed out above the starter. From what I have read this is do the HPOP going out and the shaft smacking the cover. Now just to hope there is no damage to the branch tube.

Right now I am looking at buy 2 reman heads and putting on it. This truck has 162000 on it and I use this to pull a 7600lb trailer anywhere from 200 - 1000 miles a week. Not to mention it getting used when I am home to pull our 21' boat (4500lb aprox)

From what I have stated what are your guys advice? I am going to do a coolant pressure test to just make sure I don't have a cracked cylinder cup. I know it is a long shot for it to being something that simple but I guy can wish.

My parts list is as follows;
EGR Delete
New Oil Cooler
New HPOP
New Head Gaskets
ARP Head Studs
2 Reman Cylinder Heads
Used Rear Engine Cover
Clean and Lube Turbo

Also what would be the best way to flush the coolant system? This fuel could have only been in the system for around 2 hours max. It was not in there long enough to over pressurize the reservoir. So I am guessing then the HPOP when the rest happened.

I am going to be doing this all with the cab on so any tips would be awesome.

Thanks in advance

This is how far I have got into it so far. Only been working on it for about 20 min
 

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Big dumb *******
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When the STC fitting blows apart, it can push the rear cover out like you mentioned, but that happens up top behind the HPOP. You said it was pushed out above the starter....I personally don't know why it would do that there. Is that oil or fuel in your coolant? Looks like fuel to me.
 

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Discussion Starter · #3 ·
It is behind the hpop sorry. Im pretty sure it's fuel. Is there anyway to test it to find out if its oil or fuel?
 

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Pull the motor Its really not hard if the cover is broke it has to come out anyway. pull the turbo & up pipes disconnect starter transmission pull front accessories radiator and intercooler pull the upper radiator support motor comes out the top. Grill stays in as does hood.
if it is fuel it will have funky smell like paint thinner.
Add new lifters to your list make sure you have updated turbo feed and drain tubes napa carries lower gasket set felpro fairly cheap good quality. I would put new hoses tstat and water pump in now fuel is hard on rubber. when you get it back together add some dawn dish soap to radiator fill it with water warm it up flush it out dawn breaks the fuel down so it comes right out.
 

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Big dumb *******
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It is behind the hpop sorry. Im pretty sure it's fuel. Is there anyway to test it to find out if its oil or fuel?
I'd think you'd be able to smell the diesel if it were fuel.
 

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Discussion Starter · #6 ·
I went out this morning and looked at my coolant sample again. Smells like fuel and burns like fuel, so it must be fuel :) As for pulling the motor, I can't do that since I don't have a cherry picker big enough or a stand that will hold it. I have to do it inside the truck. I know it is going to be a pain to do it that way but that's how I have to do it
 
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