I am not getting any fuel through the IP. It sounds like there is a shear point in the pump that fails and is fairly common. I have not had it off yet but I will do so today to confirm. Does anyone have a good used pump? Also what do I need to do to make sure everything lines back up when doing the removal and install?
I guess since this a first post for a Newbi I should have done an introduction first. Please forgive my manners. I have driven Ford diesels for most of my life. Mostly 7.3's but I picked up this 85 with a flat bed a few years back. It quite on us last year and have just not worked on it untill now. Hope to get it going soon because it is still a good truck with good AC.
To remove the IP, DO NOT remove the gear cover. I know all the manuals say to remove it, but you'll play heck trying to get the gears timed properly. Best to set the crankshaft to #1 TDC by using the dampner notch and timing tab. Remove the oil fill and you'll see three bolts and a locating dowel.
They hold the IP to the gear and if you make note of the locating dowels position, the new/rebuilt one will go in, in time. I would remove the steel lines from the IP to the injectors, one at a time, and tag them as to which injector they go to as the position of each line is NOT interchangable. There is a member that has access to rebuilt IP's at a good price. I can't remember which one of two, so hopefully he will see this thread. Otherwise, I can recommend MidWest Fuel Injection. Lots of negative threads and comments about Pensecola Diesel.
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Thanks for the replies. I have heard that about the WP bolts but it has not been off lately. It is good to know about the gear cover and marking the lines. When the truck quit it was just sudden like it ran out of fuel. We have tried a lot of different things to get anything through the IP. The metering valve sylonoind seems to be doing what it is suppose to. Like I already mentioned it just seems like something completely failed inside the pump.
I am still trying to find a good used pump. I would think there would be a lot of them out there but I guess not. I know someone mentioned a place in Florida to stay away from for rebuilds. There is a place in Memphis Tn. (DCP parts, Inc)that has a rebuilt for $305 with shipping. Does anyone know anything about that place. There is also a used pump on Ebay for $49 starting price with no bids. The guys says he took it off of a truck from a junk yard. I wonder if its worth the chance on that one?
Buying any used mechanical part on Flea Bay is a gamble. I have never heard of the guys in Tenn. so I can't comment. Price doesn't always determine the quality of the rebuilt or what parts are in fact replaced. I would call them and ask for an itemized list of parts replaced and services performed (bench testing, calibration etc.) and make a decision based on the information provided.
Removing IP- It is not necessary to time the engine first. Remove all the steel high pressure lines from the injectors-leave them attached to the IP. When the pump is on the bench you can remove these lines (4 at a time, they are clamped together) and install them on the new IP. If you remove the inlet fitting from the IP there is enough room to pull the pump back far enough to clear the mounting bracket.
The shear point you refer to is in case of IP seizure. If the shaft has indeed sheared you must determine the cause of the seizure before you replace the IP.
You can remove the top cover of the IP and you will see the top of the governor weight cage at the front of the pump. Bar the engine over or crank with the starter. If the cage does not spin the IP is seized. If the cage does spin with the gear the IP is not seized and may be repairable. Remember- a seized IP is not an acceptable core for a rebuilt exchange unit. You may be subject to a core charge.
When you say we need to find a cause if the pump is seized I assume you are saying that there could be a cause not related to the IP. What are the known problems outside of the pump that could cause a siezure? Bad diesel? It does look like the timing gear is in good shape and is turning the pump shaft like it should as seen through the filler neck location.
Drain the fuel and remove the top cover. Spin the shaft and see if anything moves inside. If not, she is seized.
A pump seizure on a running engine is usually caused by contaminated fuel or in the case of older style 6.9s, possibly a broken up elastocast ring in the governor. This was a plastic flex ring discontinued in the late 1980s. Evidence of a bad elastocast is what looks like coffee grounds in the pump.Also, while holding the drive shaft stationary, you should not be able to move the weight cage more than about 1/16" and it should snap back.
If contaminated fuel is the cause you must address that before replacing the pump or the new one could seize as well.
Another common cause of IP seizure is water pump replacement- Ford changed the design of the original water pump and 2 bolts must be replaced with shorter ones (usually supplied with the new pump) The longer bolts will press against the pump drive gear cocking it and causing a mis-alignment in the IP. If you didn't recently replace the water pump, this is not your cause.
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