Its very common on Ford diesels from what i hear from years 03 trough 06 they coated the inside of the tank with a rust preventive coating looks somewhat like that aluminum roof paint flakes etc. I change em about every 10k but this time the rail filter was really packed with them , upper filter was not though which is good . So thats the fuel pump on the rail ? None in the tank ? If it is a bad pump im gonna install an airdog 2 and a fuel pressure gauge on dash and be done with it . Gonna stop by Ford get a regulator today and a gauge kit for it too , let ya know what turns out . I really appreciate your patience with this , im really trying to learn my way around these 6.0's had a 7.3 for years wish i had her back now ! Never had to turn a wrench like this on that one ! Thanks again !

 

No worries man, we're all here to help!

You can get a cheap fuel pressure tester from Harbor freight, hook it up to the bowl, route it out of the hood to the windshield and trap it down with one of the wiper blades, then take it for a ride. You need to see what fuel pressure is while driving and getting on it. A lot of times it will be fine at idle, but under a load it will drop off terribly. With all the shavings you had go through I hope the filters caught all of it, if not you may be in need of some replacement injectors. I can't imagine anything getting past that filter on top of the motor though, they're really good.

FWIW, I never make it 10k on fuel filters. I can notice a fuel pressure drop before then. I typically end up changing mine about 5k-7.5k miles.

 

Gonna do that today!!!! You da CHIEF BOMB

 

Just reading through, WOT does mean Wide Open Throttle, yes sorry about that. Trying to wrap my head around your issues here...

 

Ya its OK i am the student after all!! Just wanted to let you know where I am with this, got the fuel gauge but couldn't find a MM to NPT adapter locally anywhere for the fuel pressure gauge. So thanks to the brilliance of FORD Engineer's I will be waiting on a 10 buck adapter to arrive by UPS , so twiddling my thumbs next few days!! Thanx FORD!!!!!!
Btw did get a blue spring regulator rebuild kit from IPR for $70 dealer wanted $271 for the entire unit, what a con game huh

 

Hey just wanted to give ya all an update on this beastly 6.0, turns out the EGR cooler sprung a good leak which caused the engine to go into the limp mode. I had been adding about a quart a week to the Degas bottle now I know why. Now in the process of installing an IPR EGR delete kit, replacing the oil cooler with a bulletproof and updating the hpop etc fitting. Let ya know how it turns out. Btw fuel pressure was good 52 PS I, department scan with a snap on showed no other codes or faults not even egr

 

I've never heard of one going into limp mode because of coolant leakage though. My headgaskets were so bad once that when I shut the truck off the coolant leaked into the cylinder and actually hydrolocked it on me, never went into limp mode. Were you burning that amount of coolant, or just pushing it out the degas bottle?

Your fuel pressure... was that at idle, WOT, etc?

Sounds like you've got a good plan of attach though!

Do you have a coolant filter on this truck? Now is a great time to add one if you're doing a new oil cooler. I'd recommend an entire coolant system flush too.

 

Hmmm a coolant filter? Have to look into that, thanks for the advice!! At wot the fuel pressure stayed pretty steady maybe dropped 2 or 3 pounds so I'm calling that good ( I hope)............ hope to have her all back toghther by the weekend , doing it by myself nights after work so its slow going, but i will get there!!! Really don't think its the heads no water leaking or dripping from tail pipe so keep my fingers crossed on that I'd hate it if i got her all back together then found the gaskets were blown!!

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Btw did get the cooler out the other night its wet as heck in there so I think I'm on right track with it if I wasn't so damn stubborn I'd of paid the 2 or 3 grand and had dealer do it

 

If the EGR cooler was/is blown, you can pull the EGR valve out of the intake manifold, it will be wet in there. Sure sign.

FWIW, all the time's I've blown headgaskets, I've never had coolant coming out the tailpipe.

You sound like you're on the right track.

For coolant filters, I use the http://www.dieselsite.com/coolantfiltration.aspx one, and Sinister makes a real nice looking kit now too, same thing, just more "bling" to it...

 

Ya I cleaned the egr twice in the past, first time was pretty coked up,the second time pretty clean. That's because it was gettin steam cleaned as I drove!! Ha ha another innovation from ford!!