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Power Strokes
6.0 Tech
Repeated copper washer failure.
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[QUOTE="Twinboys, post: 1419219, member: 19672"] Nearly a year ago, I was experiencing low power and fuel smoke and diagnosed a leaking injector o-ring. Since the 03 was new to me with 260k miles and a family road trip in the near future, I replaced all 8 injectors. A couple other injectors I pulled were burnt on the bottom, so I did some research, bought the tool, and followed advice to replace all 8 injector cups at the same time. I had two failures after that in 5 and 7 and the bottom of the cups had three radial cracks and the bottom blown out. I assumed it was because I wasn't able to fully seat those two cups with the heater box In the way. I removed the box and made sure the new cups were driven in fully. Since then, I have had several other cups go bad the same way, so I made sure to hammer the new cups down fully. Then I got a couple copper washer failures without blown cups. The next time, I removed and inspected all 8 injectors and inspected all 8 cups (all good), and, as always, reinstalled with new seal kits (O-rings and copper washer). I bought 8 new hold down clamps and made sure clamp hole threads were clean (as always). I installed them with a new torque wrench and discovered that my old wrench was a little weak. I increased from 24'# to 26'# with the new torque wrench, and thought I finally had the mystery solved. Now another failure, and I have to go rescue the truck from some farmers yard 100 miles away. All of that explanation to finally come to my question: In my effort to make sure the cups are fully seated, am I now damaging the combustion seal surface of the cups? Since it is impossible to hold the tool precisely centered when pounding, after making contact with the bottom, I kind of push the tool up the opposite way of gravity, and give a few extra raps to make sure the bottom is tight all the way around. I watched the video of the guy demonstrating the tool and he just haphazardly hammers away. I figured that was just to show how simple and idiot proof it was and to entice me to buy the tool. Thoughts? [/QUOTE]
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6.0 Tech
Repeated copper washer failure.
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