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Injector cup install gone wrong on a 6.0 in Nashville | Diesel Mechanics - Free To Speak

Injector cup install gone wrong on a 6.0 in Nashville

Was doing a set of injectors on a customer's F-250 last Tuesday. Everything was going smooth until I torqued the last hold down and heard that sickening pop. Pulled the cup right out of the head. Oil started weeping immediately. I've done these jobs before but never had a cup let go on install. Ended up having to pull the head, send it to a machine shop, and have them put a new cup in with the right sealant. Customer wasn't happy about the extra 2 days, but I ate the labor on the head pull. Has anyone else had cups fail during install, or was this just a bad casting from the start?

3 comments

3 Comments

christopherh791mo ago

Sounds like one of those deals where the parts themselves are the weak link, not the work. I've noticed it's the same with anything mass produced these days, you know, like phone chargers or even water hoses. You'll do the exact same install ten times and the eleventh just decides to fail on you, no rhyme or reason. Bad casting or bad batch, probably got a Friday afternoon part, which is why I always keep a spare cup on the shelf now, just in case. Good on you for eating the labor, that's the kind of thing that keeps customers coming back even if they gripe for a day.

jamie8041mo ago

The "Friday afternoon part" thing hit home for me. I had a brand new thermostat fail right out of the box last month, same exact model I've installed a dozen times without issue. You're right about mass production, it's like they rush everything out the door these days. Keeping a spare cup on the shelf is smart, I've started doing the same with a few common sensors after getting burned twice in one week. Customers don't always see that side of it, but they remember when you make it right.

alicemurphy1mo ago

Honestly, 6.0s are known for cups pulling when the block is cold and the injector hold down torque sequence gets rushed, so I'd blame the install procedure before I blamed the part. Machine shop sealant jobs fail too, and eating the labor just covers up a mistake that probably was a preventable cracked counterbore from a dirty reamer.