GEN 2 Bolts shearing—High Pressure Fuel Pump

Antho said:

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Maybe the tech used 89 ft.lbs.

Hi Here is my 2 cents

I looked at the 2018 pump cracking housing recall that FordTechOne made reference too. It's not a really simple replacement procedure, particularly if a person was inclined to take a short cut or inadvertently over tighten a bolt. Now what would happen if a bit of lubricant got in the threads. This pump lost its oil tight seal when the first bolt broke. I have seen technical references on torque specifications for bolts, same bolt but different torque specification depending on what's in contact with the threads. It varies quite a lot depending on tightening dry, with oil, with anti seize compound, or what ever else, all different. Could it be as simple a reinstalling a few times has polished the threading surface a bit. Same torque setting, the slipper the thread surface, the tighter the stretching pull on the bolt is as it's tightened to the same torque specification. Then there was the Torque Stage 1 tighten 89 inch pounds and then torque Stage 2 45 degrees. If the initial Stage 1 tightening varied toward the tight range, the last 45 degree (1/8) turn could place the bolt beyond its stretch range. My thoughts, partially driven with the why installing a new head has come up twice on this tread.

This is really interesting, please keep us posted

Interesting discussion guys!

Nothing new yet. Ford gave them orders to tear it down to a point, measure some things, and report back. Slow process. I did get a new limited expedition as a loaner tho!

Well the saga continues. Dealer put all new parts in, including a new rocker, and the tech noticed an odd ticking sound when they fired it back up. Thought maybe the new pump was faulty so they tried a new pump, but the ticking is still there. Now they're thinking something with the cam is bad and now want to put a new cam in it. Waiting on Ford to approve that I guess. More to come...still such an odd deal.

At this point, just get a new engine!

Dealer just called. The cam on the passenger side is twisted. No idea how, but apparently it is and that's causing the failures. New cam came in but it got damaged in shipping. None available anywhere I guess. Mid next month Ford says for another cam.

So...anyone got a cam laying around

Proflyer said:

So...anyone got a cam laying around

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I bet a call to RMB motorsports and you could have a whole new set, maybe pay the difference between labor/parts to install all 4 new cams with a "little" different lobe structure!

Muchmore said:

I bet a call to RMB motorsports and you could have a whole new set, maybe pay the difference between labor/parts to install all 4 new cams with a "little" different lobe structure!

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I actually floated that idea...no go since it's warranty work....

Proflyer said:

Dealer just called. The cam on the passenger side is twisted. No idea how, but apparently it is and that's causing the failures. New cam came in but it got damaged in shipping. None available anywhere I guess. Mid next month Ford says for another cam.

So...anyone got a cam laying around

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Sounds like if a Gen 2 needs parts these days, you would be in the same boat as owning a new Gen 3 and the lack of service parts. Talk about a shortage these days. Well at least you know what it needs.

Proflyer said:

Dealer just called. The cam on the passenger side is twisted. No idea how, but apparently it is and that's causing the failures. New cam came in but it got damaged in shipping. None available anywhere I guess. Mid next month Ford says for another cam.

So...anyone got a cam laying around

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Probably been like that since new, don't know how a cam can get twisted.