Another HPOP leak - Diesel Forum - TheDieselStop.com
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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks 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 7.3L Power Stroke engine.

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Old 03-18-2008, 05:28 PM   #1 (permalink)
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Another HPOP leak

I recently discovered that I had a leak on top of the engine and isolated it to the HPOP line going to the passenger side. I replaced both O-rings on the lines in the drain plug as well. Cleaned up the valley real good and a few days later dripping on the driveway again. Cleaned it out real good again, took it for a 50 mile drive and popped the hood. I found a small oil accumulation in the front under the HPOP. I used a search mirror and a flashlight and I can't isolated the leak to a specific spot, but the bottom of the pump is wet with oil. I'm assuming its a gasket from the pump to the block. I wanted to see if anybody has had this leak and if there is another possible location. If anybody knows the part # for the replacement gasket and some advice on the job ( I will be doing this myself) that would be great.
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Old 03-18-2008, 06:06 PM   #2 (permalink)
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I know I've seen people talk of a fitting on the back of the HPOP, and I believe they call it non-serviceable.

Someone else will chime in,,,
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Old 03-21-2008, 12:37 AM   #3 (permalink)
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I still haven't been able to locate the leak. Any help would be great.
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Old 03-21-2008, 07:53 AM   #4 (permalink)
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make sure it is your hpop leaking and not something else clean run and re-clean as needed to determine the source of the leak there is only one unservicable plug on the hpop according to ford but international sells a repair kit for the plug but the only down side is theplug is sealed in the port from the factory with speacial sealant so you may have to heat it in order to get it out the only down side is if you strip out the threads in the hpop removing the plug your done you have to get a new hpop or send it to someone you trust for repairing it I do not but if its just the hpop gasket leaking thats an easy fix the gasket is about 15 bucks or so and with the right hand tools you can repair in 1 or 2 hours so good luck
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Old 03-22-2008, 08:17 PM   #5 (permalink)
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Glock,
Thanks for the advice. I saw the post on the FAQ'S about the non-serviceable plug and it kinda freaks me out to think that might be it. Lets face the pump is expensive and I'm poor. Are there any other gaskets that I might need to replace when I remove the pump to replace the bad one?
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Old 03-22-2008, 08:57 PM   #6 (permalink)
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There is a plug on the back of the HPOP. I forget what size it is but if you take it out you will notice a small 'O' ring in it. The plug was leaking on my truck twice & last Spring on my return from Arizona, it was leaking REAL bad when I got to Branson. Before, all I had done was tighten up the plug & it seemed to work. On the last time I was running an Edge Attitute @ #3 setting & I believe the pressure increase @ the HPOP was to great for the 'O' Ring and caused it to leak again. I replaced the 'O' Ring & tightened the plug back down It has not leaked since. It just may be your problem. Hope this helps.

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Old 04-20-2008, 06:05 PM   #7 (permalink)
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DakotaDiesal

i have the same leak i thought it may be the ipr but does not look that way i have not looked into the procedure for removing the pump and replacing the gasket let me know what u find as i am in for the same repair

200k on my 02 350 and running like a top man i love the 7.3
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Old 04-21-2008, 09:57 AM   #8 (permalink)
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If it is oil, Possibilities/ Repair;
1. IPR O ring-Replace O ring
2. HPOP Non-Serviceable Plug-Replace O ring, clean threads, apply threadlocker, install plug, new O riing and tighten
3. HPOP Gasket Bad-Replace gasket
4. Cracked HPOP-Replace
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Old 04-21-2008, 10:54 PM   #9 (permalink)
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DakotaDiesal

found mine ... did the mirror trick and see it dripping from the bottom of the pump wont be able to tell if it is a cracked pump or bad gasket till i get it out of there
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Old 11-08-2012, 10:27 PM   #10 (permalink)
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Did you ever find what the culprit is? Have my pump off now and thought it was the gasket but it looks perfect....now I'm stumped. Would a crack in the pump be obvious? There are a bunch of casting marks on the pump that look like they could be cracks, but I don't think they are. Guess I'm going to replace all the O rings too to try and cover all the angels. Wish I would have gotten a mirror to see exactly where the oil was coming from under the pump.
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Old 11-09-2012, 10:57 AM   #11 (permalink)
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Replace all the O'rings. It's doubtful it's the gasket as the gasket is under very low to no pressure. Dieselorings.com sells a kit of o'rings. Replace them all, and get the "non-serviceable" plug replacement. All the o'rings on the hpop degrade. You will see what I mean when you take it apart. Use Viton 90 o'rings and you won't have this problem again. The non-serviceable plug is supposed to be replaced with the pump on the bench, but it can be done with the pump on the truck. The surface tension of the oil will keep the little plastic check ball in place. Just don't blow into the pump with the plug out. The plug came right out in mine. No need to heat, or anything. Where I had problems was one of the pump mounting bolts was seized and I could not get it loose. If I ever have to replace my HPOP, I will have to cut the pump to get the passenger side mounting bolt out ...

My leak started with the lines, but soon after the non serv plug and the drain plug at the back was leaking too. The IPR oring also had issues. They all looked like they had partially dissolved.


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Old 11-11-2012, 09:45 PM   #12 (permalink)
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Went ahead and replaced all of the o rings...drove down to Greely to get the parts from Bob at dieselorings.com. Saved time on shipping them, since I had to get my truck up and running to plow. At least I thought I did, turns out the foot or so of snow we got pretty much melted off the roads. Was the non servicable plug that was leaking badly...it came right out with out the slightest bit of trouble. Ended up pulling the whole pump off and maybe it could have been done on the truck but I think it would have been hard to get the treads clean enough to get a good seal with the new locktite.

Jeff
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Old 11-12-2012, 12:47 AM   #13 (permalink)
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Glad to hear you've solved your problem. It's nice to be able to park in the driveway again, eh? I can't stand oil drips on the driveway. Keep drip pans handy to throw under my son's car when he visits ...


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Old 11-13-2012, 08:10 PM   #14 (permalink)
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Yup, would have needed a big drip pan...it was leaking massive amounts of oil!!!
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