Hey guys
I am another one of the unlucky 2003 6.0 owners. I have had the HOPO changed 4 times in about 50,000 and even the dealership repairs last like the typical garage repairs. I have done every preventative measure but still end up broke down. Now to the point I am going to try myself and see if the repairs last any longer.

 

welcome to db.

 

Welcome! and what exactly are the troubles your having?

 

My biggest problem has been the HPOP which has been changed four (fixing to be five) times in 57,000 miles. The last time it lasted almost 15,000 but it had the upgrade line and the cooler changed and the truck has had the head bolts redone , the egr bypass work and get a oil change every 3-4 thousand miles. all the injectors and glow plugs which were changed 100 miles before last HPOP was done. The truck is a F550 crew cab , 4x4 dually.
Its only used three or four times a year to move my RV and a daily with less than 60 miles a day five days a week. But my repair cost have exceeded 15,000 oh yea the ICP was replaced and the new harness installed as well. Just a note all but one of the HPOP were installed at the Ford dealer.
Its been a Ford nightmare!

 

hmm. that's very strange. there has to be a problem else where making the hpop fail. hpops are pretty tough, there not something you should be replacing regularly. is the oil cooler plugged up? maybe im thinking that its clogged somewhere, and only the 100% pressure of a new pump keeps it going. I would research what cuases an hpop failure besides just aging and poor oil. that should give you some sort of lead. also I would bring it to a high performance diesel shop and have them run a full diagnostic. that could also lead you to the actual problem. not sure on the 6.0s, but if a 7.3 is low on oil or has a HP oil leak it usually wont fire. or if it does it takes a while. is your truck deleted and tuned or all stock?

 

The egr has been deleted and all the filters and coolers were replaced with the last HPOP and there is no chip and I have never had a chip in it . The last mechanic was a master mechanic at ford and he said he expected no problems as everything that could cause issues was replaced and I agree it should have not had any issues but it does and the oil is changed every 3,000 with a high quality oil so I am at my wits end!

 

yea that's a mystery. but then again the dealer could be not telling you what the actualy problem is, I know if you walk in there and say "my hpop is broken again, I need you to fix it" there not gonna diagnose anything, just charge you whether it fixes it or not. if I were you I would find a shop very familiar to 6.0s and have them run a diagnostic, it will tell you everything you need to know. im stumped, I feel as if the oil flow is getting clogged up somewhere but I could be wrong. they'll charge you 80$ for the diagnostic and youll have your answer. ps I got my hpop put in for 625$, with a diesel site adrenaline pump, that dealers gotta be loving your wallet!

 

The bad part is I have had three different dealers do the repairs and every time I get a fill diagnosis run. I am gonna do the hpop myself this time and do a full major flush job on the engine and see how it works this time. I do appreciate your advice and if you have any more suggestions or clues to anything I can do please let me know!

 

I have been looking at the upgrade oil coolers and I am wondering which one have people had the best luck with? I am fixing to change the hpop and have already done the egr delete on the engine which does not have a chip or programmer all stock except the delete.

 

bullet proof diesel has a great reputation. I don't know how mechanically inclined you are, but if you plan on making future repairs yourself, id invest into auto enginuity, its kind of like a scanner, but reads what every sensor is telling you on your laptop screen (or tablet). I haven't gotten myself to buy it yet, but im definetly considering it. Im pretty sure its around 650$ for it, but youd never have to get it diagnosed again, and youd be able to fix it yourself. im sure some of the 6.0 guys will chime in with better ideas. id post in the 6.0 section.


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