Goodbye Ford 6.7 HPFP
Well, its over, adios Ford. If any of you have read my previous posts you can tell I have loved both Ford and my 6.7, despite living thru hell a few years ago with my earlier 6.0. The love affair has cooled and we are parting ways. Oh the truck still looks great, runs fine, gets good mileage, and will pull an oak tree out by the roots, and it is also still under warranty, except apparently for the HPFP. So whats my problem? HPFP discussion with Ford dealership today confirms what I have been reading, that although the HFPF is technically still covered by the warranty, Ford will likely not honor that warranty if the HPFP fails, and the dealership is recommending that in the event it does fail, that I contact my insurance co at the same time I tow the truck in for repair.
According to the dealer, the reason Ford will usually not warranty the HPFP is that Ford has taken the default position that the only failure mode for the HPFP is fuel contamination at the fault of the owner, unless the damn pump just does something like comes loose inside the engine. Further it is clear that the DFCM does not protect the HPFP from suspended water in ULSD, even if you have never have water in the DCFM or have never had a "water in fuel" warning. And since you as the user cannot be sure you do not put fuel in your truck that is contaminated with suspended water, its really only a matter of time and chance until you have a HPFP failure.
So since the HPFP repair can cost up to about 25% of the cost of a new truck, its a little risky for me to just go by faith on Fords "Hope it doesnt fail and Change at your cost if if it does" route. So if the HPFP fails, this is the claim process as related by the dealership based on there experience with HPFP warranty claims to Ford.
1. tow the truck to the service dealer
2. authorize Ford to tear down the engine at my cost, which will be reimbursed if the HPFP is covered by warranty.
3. servicing dealer documents, photos, sends parts to Ford for warranty determination
4. somewhere between 30 to 90 days later Ford will most likely deny the warranty, which the dealership say has been the norm since Oct 2011.
5. In the mean time I have no truck, unless I authorize them to fix the truck at the time of teardown. Cost will range from $8k to $15k depending on whether injectors and other internal damage has occurred, and yes, I will still have the same HPFP concerns after the repair.
Why am I concerned if it will fail? After a lot of reading and discussing seems yes the HPFP does really fail, and the first tell tale sign is small aluminum specks in the DFCM. So I changed the fuel filters today and examined the DFCM in detail by cutting it apart and spreading out the pleats, and there there were, very small bright silver non-magnetic specks of metal, ie aluminum imbedded in the filter element.
So my logic is now, sell/trade the truck and avoid a probable $10k+ repair bill (just a matter of when it self destructs) and put that $10k toward a new truck that does not have the non warranty HPFP concern. That means either GM which actually does have the same HPFP failure issue but GM is covering it under warranty, or Dodge which does not have the HPFP problem.
For the record the tuck is a Job 1, purchased in May 2010 and has 60119 miles on it, almost all of it pulling a 8k lb trailer along the interstate from Louisiana thru Colorado and into Montana and Canada at 65-70 mph. Oil has been changed and filters replaced religiously, never had a drop of water come out of the DFCM, never had a "water in fuel warning", almost all fuel from Shell, Loves, etc. Absolutely no slime ever in DFCM, no dirt, grit, or anything else when filters changed. Ford diesel fuel additive has been used continuously since the truck was purchased. Also, at a cost of $3k is has an extended 6 year bumper to bumper Ford warranty.
Sorry bout this, I really do love the truck and accept the fact that the HPFP and other parts may fail, but at risk not to be honored by Ford when operated and maintained by the book while still under warranty? Nope not after spending $8k+ on my 6.0 two weeks out of warranty when the EGR cooler split. Fooled twice, shame on me.