Ford Doctor
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Everything posted by Ford Doctor
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From the album: General Mechanical Failures
We are not sure what started this but a good guess might be a seized or sticking valve. Once a piston strike occurs anything can happen and the entire head of the valve broke off. It is amazing how this engine continued to run with the valve bouncing around in the cylinder. The connecting rod and the piston were very accommodating, don't you think? This type of failure always brings a line of onlookers in the shop. More shock and awe!© Keith Browning
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From the album: General Mechanical Failures
This 6.4L valve rocker shows a failure at the fulcrum. A sharp eye will also reveal that the pivoting tip is missing which is generally the root cause of this and it is not uncommon to find broken rocker arms or rocker arms that have "fallen off" because of excessive wear or other valvtrain failures.© Keith Browning
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From the album: General Mechanical Failures
Front and center is a valve that has broken at the keeper end. If you look closely you can see the tip of the valve just to the tight of the spring and the keepers down in the head at the lower right. Sometimes parts just break.© Keith Browning
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From the album: General Mechanical Failures
The techncian who found this stated that the head of the connecting rod bolt was found in the oil pan. This also illustrates how close the moving parts inside the crankcase are. You are looking through a hole blasted in the windage tray that is part of the upper oil pan.© Keith Browning
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From the album: General Mechanical Failures
A broken crankshaft falls under the category of shock and awe when they fail. Not a common failure at all this can happen due to a defect in the metal and sometimes when an engine is operated out of it's design limits. Read that as you wish.© Keith Browning
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From the album: General Mechanical Failures
A misfire and low compression led to discovering this burnt exhaust valve. Burnt valves can have several causes that lead to a poor seal between the valve face and the valve seat. These causes include cylinder overheating, defects in the valve and or seat, fuel injection concerns and even EGR problems that fail to control combustion temperatures. A look at the burnt up tip of the glow plug indicates that temperatures in this cylinder were pretty high.© Keith Browning
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From the album: General Mechanical Failures
This valve was extracted from the cylinder head of a 7.3L Power Stroke Diesel engine. The engine had apparently not been started for some time and rust had formed in the valve guide leading to it's sticking. Above the valve is the mating push rod that was not only bent but it shattered. This is due to the piston striking the valve. This phenomenon also affects 6.0L engines as well. Not very common.© Keith Browning
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From the album: General Mechanical Failures
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From the album: General Mechanical Failures
A damaged oil pump gear caused by debris picked up from the oil pan. In this case needle bearings from a failed cam follower.© Keith Browning
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From the album: General Mechanical Failures
A damaged oil pump gear caused by debris picked up from the oil pan. In this case needle bearings from a failed cam follower.© Keith Browning
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From the album: General Mechanical Failures
A roller cam follower that has lost the needle bearings and ground away on the camshaft lobe. The needle bearings ended up in the oil pan where they were picked up through the oil pick-up screen and destroyed the front engine cover and oil pump.© Keith Browning
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From the album: General Mechanical Failures
The crack in this 6.0L engine block is at the edge of the oil cooler reservoir. The engine oil appears green because ultra-violet tracer dye was added to it to aid in diagnosing the oil leak caused by the crack.© Keith Browning
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From the album: General Mechanical Failures
Here is the crown of a cracked piston. The crack allowed combustion gasses and heat to leak though burning a hole like a blowtorch.© Keith Browning
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From the album: General Mechanical Failures
This 7.3L Power Stroke piston has a deep crack from the bottom of the wrist pin bore to the crown. The failure was thought to be caused by stress or heat.© Keith Browning
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From the album: General Mechanical Failures
This is a cracked engine flex-plate. Similar to a flywheel a flex plate provides a connection between the engine and an automatic transmission. There are several potential causes for this type of failure like improper assembly, engine/transmission mis-alignment, excessive crankshaft end play and a worn out front pump bushing in the automatic transmission. It is also thought that engine or torque converter imbalance can cause flex plate failures.© Keith Browning
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From the album: Oil And Water
An oil rail port-plug o-ring has deteriorated causing low injection oil pressure. These plugs along with the oil feed stand pipes are found in both 4.5L and 6.0L Power Stroke diesel engines. The common symptoms are crank/no start when hot and long crank/no start after a cold soak. Lack of power and stalling can also result from this.© Keith Browning
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From the album: Oil And Water
This is what front engine cover cavitation looks like. This is the result of cavitation erosion caused by the water pump. The resulting hole allows coolant to leak directly into the crankcase. Largely affecting 6.4L PSD engines the cover has been redesigned to prevent this from happening.© Keith Browning
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From the album: Oil And Water
For some reason a lot of 6.4L front crankshaft oil seals like to leak. You can clearly see oil pooling where the shaft and the seal meet. Notice how oil is well distributed around the front of the engine. Oil will get thrown off of the crankshaft dampener and blown around by moving air from the engine cooling fan.© Keith Browning
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From the album: Oil And Water
6.0L PSD engines were known for bed plate oil leaks which can be caused by improper disassembly and assembly of the front and rear covers that can stretch the lower spaghetti gaskets. But what you are looking at is the sealing surface of the cylinder block that mates with the lower bed plate. The casting and or machining here is absolutely horrendous and with a surface like this the thin rubber seal simply cannot effectively seal. Ford has endorsed the use of anaerobic sealant to fix this condition.© Keith Browning
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From the album: Oil And Water
Almost infamous are the high pressure oil pump output fittings where the cylinder head oil feed lines connect on 7.3L Power Stroke engines. The fittings can loosen and the o-rings deteriorate. When this happens it creates a severe oil leak that pools in the engine valley and drains down the back of the engine.© Keith Browning
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From the album: Oil And Water
Glow plug harnesses are a comon source for oil leaks. This 6.0L glow plug harness is of the newer design but they still commonly leak at the o-rings and are serviceable provided they do not stick in the rocker box bores or come apart during removal. A special tool is required to remove them. Sealing in this area has been improved over the years.© Keith Browning
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From the album: Oil And Water
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From the album: Oil And Water
At the bottom of the oil cooler reservoir is the high pressure oil pump oil feed passage. The screen that filters the oil going to the HPOP can be brittle and sections may become unsecured and in some cases completely separate. It is important when servicing oil coolers to prevent dirt and other debris from entering this reservoir and ensure it is completely clean before reassembly. Always install a new screen which has been updated to a stainless steel design.© Keith Browning
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From the album: Oil And Water
Here is the reason for the damaged oil filter stand pipe in the previous image. On the lower right is the top piece of an old oil filter that was left in the cap when the new filter was installed. Always inspect for parts left behind and if a filter cap seems to be too tight and requires excessive force to tighten use common sense and STOP tightening the cap!© Keith Browning
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From the album: Oil And Water
Another damaged 6.0L oil filter standpipe. This one was broken when a new filter was installed with the top of the old oil filter stuck in the cap. It had to have been forced with excessive effort to screw the cap on completely. This is pure installer error. Always inspect the filter housing and cap for debris and pieces of the old filters left behind.© Keith Browning
