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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 03-06-2008, 07:40 PM   #1 (permalink)
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diesel fuel in coolant tank

I have a friend that has a 1999 F350 7.3 and has diesel fuel in the radiator fill tank. Any ideas? Maybe cracked injector tube or o rings.Any ideas on how to find which cylinders are affected? Thanks for any help. Tommy
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Old 03-06-2008, 07:43 PM   #2 (permalink)
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Uh oh, this usually means cracked injector cups or head gasket. Usually its the injector cups if you have diesel in the coolant.
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Old 03-06-2008, 08:23 PM   #3 (permalink)
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hey there, im going through the same thing. just went to do a coolant flush and found diesel in the overflow tank.

I am going to replace all 8 injector cups, so i don't have to go through this again in 3 more months.

im am going to have the injectors tested to make sure that they were not damaged by the coolant.

The shop that i am taking it too doesn't have to pull the heads because they have a special tool to pull the injector cups(coppers).

if you or the repair shop doesn't have this tool, then you have to pull the heads to get the coppers out. thats when things start getting expensive. lots of labor there.

coolant flush when the motors all buttoned up, flush it really good. replace your rad. cap as well because the diesel will eat the gaskets and stuff.
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Old 03-07-2008, 07:21 AM   #4 (permalink)
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Same tools required, heads on or off. Well to be truthful, 90% of the tools are the same...the important ones.
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Old 04-07-2008, 04:15 PM   #5 (permalink)
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As stated above by KANMAN it sounds like an injector cup is bad. My 2003 Excursion (80kmiles) has the same problem, smell fuel in the truck because it was over flowing at the coolant reservoir but the truck ran fine and is not overheating. Ford just confirmed it is the injector cup and will have to pull the engine to determine which one, lucky its under warranty for 3 more months.

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Old 04-09-2008, 09:52 AM   #6 (permalink)
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I have a 2001 F-450 7.3 PSD. I was pulling a trailer from CA to TN and had the same problem - injector cup leaking fuel into overflow. I had the cups and injector O-rings replaced, but then had the issue of having the radiator and a couple of cooling hoses start to leak. The shop told me that it was because the diesel had eaten away at the O-rings. I checked with Ford and two other shops and both confirmed that diesel can eat away at the O-rings and the gasket material between the tank and radiator (would only hold about 6 - 7 lbs pressure). Since the truck was over 100k miles and all original, I replaced the radiator, water pump and hoses as I did not want any future problems. When replacing the injuector cups they did not have to remove the heads either.
Good luck with yours.
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Old 04-10-2008, 08:05 AM   #7 (permalink)
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little update on my situation.

took it into the repair shop(not ford) and had them do the work. took about 2 weeks to get the truck back, but that was because the injectors had to be shipped out to get tested. one injector was bad, so had it rebuilt and the rest of them gone through and cleaned up. got the truck back and all is well now. have had it back for a couple weeks now and the coolant is still clean!!
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Old 05-22-2012, 11:27 AM   #8 (permalink)
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1999 f-250 diesel

I bought my son a 1999 f-250. We found fuel in the coolant system. I've had Ford and a private diesel mechanic look at it and am being told 4k - 6k to fix. They say it has a injector cup leaking maybe two. they say it needs to have the cylinders machined, replace cups and injectors, hoses, thermostat and what ever along with the coolant flushes. Won't know if heads are cracked until compression check he said? I paid 11k for the truck 6 months ago. Is this worth the cost to repair? Any advise?
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Old 05-22-2012, 12:00 PM   #9 (permalink)
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Quote:
Originally Posted by smurray View Post
I bought my son a 1999 f-250. We found fuel in the coolant system. I've had Ford and a private diesel mechanic look at it and am being told 4k - 6k to fix. They say it has a injector cup leaking maybe two. they say it needs to have the cylinders machined, replace cups and injectors, hoses, thermostat and what ever along with the coolant flushes. Won't know if heads are cracked until compression check he said? I paid 11k for the truck 6 months ago. Is this worth the cost to repair? Any advise?
If they really feel the need to go that deep (pull heads and check for cracks) then they're being over-cautious, IMO. If it's just cracked injector cups, those can be replaced without even pulling the heads. A cracked injector cup won't necessarily mean a crack in the head. 7.3L's typically don't have problems with heads, except for the injector cups. How many miles on the truck? If it's under 250k, then the injectors are probably OK, but might be worth checking at that mileage.

Replacing all 8 injector cups is a full day or maybe a little more. What's needed is the injector cup tools, the injector cups themselves, a set of injector o-rings, and not much else. Replacing hoses is a good idea as well, but not that big a deal to do. The heater hoses are probably the biggest PITA, with the quick connects to the heater core. You should probably do an oil change after the injector R&R as well just for good measure.
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Old 05-22-2012, 12:09 PM   #10 (permalink)
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You will also need some special tools if you decide to do the job yourself.

Rosewood Diesel Shop has them and a how too do it on their web site. Click on injector sleeve tools when you open up their site.
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Old 05-22-2012, 02:00 PM   #11 (permalink)
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I had same issue at 206,000 miles on mine. Had all 8 cups replaced, and all 8 glo plugs, o-rings and hoses. My Ford wrench man did it in a few hours. We ran the truck with Simple Green in the coolant system to clean it out, then replaced all hoses. 5-6k is a high estimate. Doubt there is head damage. Worth the fix for me for sure. Injectors were all fine, and still pushing over 20# boost when done. 200,000 is a mid point on these trucks if taken care of, fix it ! You don't want a newer version in my opinion.

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