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6.0L Power Stroke Engine and Drivetrain Discussion of the 6.0L Power Stroke diesel engine and drivetrain in the 2003-Up Super Duties and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 6.0L Power Stroke engine.

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Old 08-14-2007, 03:08 PM   #1 (permalink)
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fuel/water separator drain stuck

This is in my '04 6.0 Excursion, 4x4 of course to make it difficult to get too.
I haven't gotten the water in fuel light in years. It recently came on though. I went to drain the separator and the plug is stuck and the hex socket head rounded. Last time it came on I was getting ready to get an oil change so I asked them to drain it while they were down there. I'm guessing they used an incorrectly sized driver to remove and replace the plug and in the process messed it up.
Options?
I've tried other sizes of drivers hoping to get it to budge, but nothing. There really is only enough room to get an allen key in there with the driveshaft in place.
If there weren't fuel inside I would just weld a nut to the plug and back it out with a wrench, but I don't think its such a good idea.
Any ideas?
Thanks
Rob
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Old 08-14-2007, 03:15 PM   #2 (permalink)
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Re: fuel/water separator drain stuck

pick up a single 6 mm allen wrench and some JB weld, glue the single allen in the hole of the plug, reinforce with duct tape ect until it sets up, then remove the old plug, pick up the newer style plug that is extended out of the hole, there are many threads on here about it and the part #.

Good luck,!!
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Old 08-14-2007, 03:17 PM   #3 (permalink)
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Re: fuel/water separator drain stuck

I have seen a thread within the last 2 weeks on this. Search or I am sure someone will respond. I can tell you that the plug you want to replace it with is from IH #2589259C91. More of a thumb screw...
Good luck
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Old 08-14-2007, 03:38 PM   #4 (permalink)
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Re: fuel/water separator drain stuck

And don't reef on It is the o-ring that accomplishes the seal, not how many foot-pounds you torque it to.
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Old 08-14-2007, 04:44 PM   #5 (permalink)
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Re: fuel/water separator drain stuck

Sorry, I searched and didn't come up with anything usefull or even close. For some reason the search engine on this forum never brings me anything usefull, unlike other forums.

I may try the JBweld. I tried it a number of years ago on a stuck recessed nut and didn't have any luck, but with a little patience that may just get this one out. Thanks

I will definitely get the thumb screw replacement plug
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Old 08-14-2007, 06:06 PM   #6 (permalink)
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Re: fuel/water separator drain stuck

The WIF light isn't to remind you there's water in your fuel and to drain it..... The goal is to drain the HFCM frequently enough to PREVENT it from coming on.

Take Care
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Old 08-14-2007, 06:12 PM   #7 (permalink)
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Re: fuel/water separator drain stuck

I am in the same boat as you. I am contemplating removing front drive shaft to allow more room, although I have never removed one before. Here is a link to a thread that I started a few weeks ago... look here
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Old 08-14-2007, 06:36 PM   #8 (permalink)
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Re: fuel/water separator drain stuck

Drain monthly and they don't strip. Mine is steal maybe?

A 6" center punch on edge of plug on 45 degree counter clock wise will
take it out. No metal from drilling. Not a lot of room on 4x4.

I think ford should make this with 13mm bolt. Not a fan of brass plug.

BL
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Old 08-14-2007, 10:15 PM   #9 (permalink)
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Re: fuel/water separator drain stuck

Try this site,,,,it should have the part number you need...

http://www.forddoctorsdts.com/articl...icle-05-19.php

hope it works...the last one I bought from International was around 12 bucks....Ford wanted $25.oo the same part....Kevin
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Old 08-15-2007, 01:30 AM   #10 (permalink)
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Re: fuel/water separator drain stuck

[ QUOTE ]
Last time it came on I was getting ready to get an oil change so I asked them to drain it while they were down there.

[/ QUOTE ]

That's what caused your problem. That plug should never be tightened greater than "just snug". The o-ring is the seal, and if you get carried away torquing it down, you'll have problems later.

If it gets to the point you need to take the cover off to drill out the plug, make sure you get a gasket kit before you take it off. The old one is NOT reusable, and you will have problems if you try to reuse it.
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Old 08-15-2007, 10:01 AM   #11 (permalink)
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Re: fuel/water separator drain stuck

How is it so many people have a hard time getting an allen wrench into the plug? Sure the front drive shaft on mine is right there, but there is still plenty of room to get the short end of the wrench into the plug. Do some trucks have the drive shaft closer to the HFCM or vice versa??
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Old 08-15-2007, 10:05 AM   #12 (permalink)
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Re: fuel/water separator drain stuck

has anyone verified if the 2008 drain with lever is a fit for the 03-07's?
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Old 08-15-2007, 10:38 AM   #13 (permalink)
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Re: fuel/water separator drain stuck

[ QUOTE ]
has anyone verified if the 2008 drain with lever is a fit for the 03-07's?

[/ QUOTE ]

That's a question I'd like to see answered! If the 2008 plug won't fit, then my question is, do I have to remove the front driveshaft to install the IH plug? I've had one I got from ITP rattling around in my glovebox for a while.
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Old 08-15-2007, 02:25 PM   #14 (permalink)
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Re: fuel/water separator drain stuck

The 2008 HFCM is completely different, sadly. No go on a retrofit, without an insane amount of work.

The plug, despite being brass, develops enough corrosion around the threads to stick it a little bit even if it's not overtorqued (and this is why people who take it out monthly don't have the problem; no time for corrosion to build up.) It's isn't really sticking all that much, but the hex hole in the head, being brass, doesn't provide very much resistance to rounding either. The plug always loses eventually.

Ford's official replacement for our pickups is a steel plug. More likely to get a little corrosion, I suppose, but infinitely more resistant to rounding out the hole. So the plug wins, and the corrosion loses the torque battle.

The IH replacement is the way to go, though. No more depending on a stupid hex hole for putting torque on it.

Duncan
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Old 08-15-2007, 02:45 PM   #15 (permalink)
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Re: fuel/water separator drain stuck

The Ford part number is 6E7Z-9c082-A

I picked one up from Ford and I think it was under $12, and it works beautiful.
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