FordExcursions.com Forums
JohnBoy
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• DFW, TX, USA |
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• Registered on 9/3/2002 |
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• 972 posts |
• 2 Vehicles
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 Posted:6/5/2005 19:17 |
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Hey Kevin....
a few phone calls to a salvage yard to see if anyone has a locator service may save you a bit of time...
it's not like that is a wear item you have to worry about it beign good or not...
good luck...
2005 6.0L 4x4 Eddie Bauer Ex
2003 6.0L 4x4 Limited Ex - traded in (BooHoo )
"The Republicans should back off and let men marry men, women marry women, and legalize abortion. In three generations there would be no Democrats." |
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CHPMustang
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• Plano, TX, USA |
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• Registered on 7/24/2002 |
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• 1,800 posts |
• 1 Vehicle
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Posted:6/6/2005 11:54 |
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Yeah those FPR metal caps are made of pot metal which is easily breakable if too much force is put on em' which all they need is just to snug.
If you haven't picked up a replacement cap yet contact Dale @ Powerstrokeshop.com or check out the upgraded heavier duty cap at Diesel Innovations 
I made it to Gilbert late Sunday but our Excursion is in Dallas Texas which means I have no wheels to get around in while in Phoenix during our visit,next time were in town we'll have one of the trucks and try to organize a get together 
Bill
Bill
2002 Excursion XLT-P 4x4 7.3L Powerstroke Diesel
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KevinsOffroad
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• Phoenix, AZ, USA |
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• Registered on 5/15/2005 |
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• 38 posts |
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Posted:6/6/2005 12:43 |
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Thank you all for your assistance. I went to the dealership, and the part is evidently not available separately...you have to buy the entire fuel pressure regulator for $160 and two days. I'm leaving for Moab with my Jeep on a trailer on Wed AM so that's not a possibility. I'm going to see what I can do locally at a junkyard first. Worst case I'll have one of the two gents above overnight me one today.
Thanks again!
Kevin
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CHPMustang
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• Plano, TX, USA |
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• Registered on 7/24/2002 |
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• 1,800 posts |
• 1 Vehicle
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Posted:6/6/2005 13:13 |
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Kevin make sure you hold onto the remaining stock parts(brass seat,spring and bolts)if you end up having to purchase the whole kit.
Have a safe trip to Moab!
Bill
Bill
2002 Excursion XLT-P 4x4 7.3L Powerstroke Diesel
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Texas4x4
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• Tyler, TX, USA |
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• Registered on 7/25/2003 |
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• 289 posts |
• 1 Vehicle
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Posted:6/6/2005 15:29 |
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| Quote: | I'm leaving for Moab with my Jeep on a trailer on Wed AM
Kevin
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You suck! I'm so jealous!!! 
I just had a bunch of friends get back from Moab over the weekend. One of 'em is still there.
=-=-=-=-=-=-=-=-=-=-=-=-=-=-
Kevin Curry
Staff Writer: www.ROCKCRAWLER.com
[email protected]
http://www.texas4x4.com
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KevinsOffroad
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• Phoenix, AZ, USA |
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• Registered on 5/15/2005 |
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• 38 posts |
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Posted:6/7/2005 14:22 |
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Ok, I guess all is well that ends well. For archive purposes, I'm going to discuss what I had to do.
First off, the cover is listed as a part number 9H323, which comes with an O ring and two torx bolts. That is not the full part number...but the dealership can look it up for you.
Secondly, the new cover, when compared to my factory 2000 model cover, is ever so slightly variant. The ID of the cover is less than one of the #2 or #4 washers (I think my bag was different...I swear that they were #2 washers) ((oh, and by the way, the Radio Shack ones are not Stainless, but they are steel)), so you have to push them into position in the bottom, slightly deforming them. That actually works out fairly well, as previously, the washers wanted to fall out when tipped on it's side to install and you had to hold the spring against it. I pushed them down the with T25 screwdriver bit and pressed them into place. I ended up with a runout of .205", measured from the seating surface without the O-ring to the seating position of the spring. It measured out like .265" when I started, when the old factory one measured out at .248", so there was some variance as well there.
In order to get the broken nipple out of the brass compression fitting, I used a #5 screw extractor. A #6 would have been better (larger) but the set I purchased at Sears only had the #1-#5. It's a Sears part number 9-52315. I also placed a 5/16" ID O-ring over the rubber seal on the compression fitting to make up for the lost rubber than was worn off by the compression nut during the first seating, just to make sure that I had enough tension to make sure that it didn't leak.
To get the compression nut off of the flared fuel return line, I first removed the lower fuel pressure line as well as the retaining bolt for the "fuel standpipe" located on the front side of the block, accessable from underneath. If you have someone wiggle the lines, you'll see where it bolts. With that loose, there was JUST enough room to wiggle the return line out of the neck of the pressure line and bend it upward CAREFULLY!!! If you snap the line off, I think you have to remove the entire front end of the engine to replace it, due to the bends in it. Make sure to replace the bolt when you're done, so that the lines don't wiggle around up top and create leaks.
Lastly, after cutting off the flare to get the compression nut off and the broken nipple out, I had to re-flare the line. I know this sounds dumb, but make CERTAIN that ALL of the components that you need to thread on to the line are ON the tube before you flare it. This includes the compression nut, the rubber seal, and in my case, the extra 5/16" O-ring that I used as an extra spacer between the rubber seal and the inside of the compression nut. I had the tip of the tube sticking out slightly less than flush with the outside of the flaring tool, which resulted in slightly less flare than I thought it should have, but even OD with the small flared donut that I sliced off with the hack-saw to get the compression nut off. The moral to the story is that you can always flare it MORE if you don't have enough the first time, but if you flare too much, you'll have to get a flat file and file down the OD in order to get the compression nut to slide over it. Thankfully my highly-calibrated eyeball got it just right the first time...no need for a re-flare OR a flat file.
Folks, I spent an extra $60 on parts and tools that I may never use again because I overtightened the compression fitting, not to mention the two days that the beast was undrivable. PLEASE do not overtighten the fitting and do what I did. Cinch it down lightly and check for leaks. If it does leak, you might want to try my 5/16" O-ring trick to add more tension to the rubber seal FIRST before you get into a situation like I did.
Anyway, I'm off to Moab. Thanks, everyone (particularly Bill, who e-mailed me directly to offer his expertise) for your assistance in my hour of need!
Very Sincerely,
Kevin
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CHPMustang
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• Plano, TX, USA |
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• Registered on 7/24/2002 |
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• 1,800 posts |
• 1 Vehicle
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Posted:6/7/2005 16:23 |
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To get the washers to seat correctly without forcing them I filed the edge all the way around to clear the cap guide fins.
The method I used to prevent the washers from falling out of the brass seat was I used a small dab of petroleum jelly as it would cleanly desolve with no ill effects to the diesel fuel system.
Kevin I wish I carried an extra FPR cap with me when on the road just for an event like this 
Let me know how the trip went when you get back home and unloaded
Bill
Bill
2002 Excursion XLT-P 4x4 7.3L Powerstroke Diesel
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KevinsOffroad
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• Phoenix, AZ, USA |
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• Registered on 5/15/2005 |
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• 38 posts |
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Posted:6/14/2005 20:37 |
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Well, I'm back in town, Bill...thanks to you. (actually, I would never have been able to leave town, lol). At any rate, I posted up about how happy I was with the trip here: http://www.fordexcursions.com/forums/posts.php?threadid=5003&postid=26410#26410. The Ex ran like a charm. I'm SO happy that I bought this thing...it did a fantastic job.
Again, Bill...thank you so much for your assistance in my hour of need!
Kevin
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CHPMustang
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• Plano, TX, USA |
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• Registered on 7/24/2002 |
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• 1,800 posts |
• 1 Vehicle
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Posted:6/14/2005 21:19 |
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Glad all went well Kevin!
Happy I could pass on some words of wisdom and a reference to a Powerstroke parts dealer that'd take care of ya
Next time we're in Gilbert we'll have to hook up to exchange pleasantries and maybe do some modding to your truck
Bill
Bill
2002 Excursion XLT-P 4x4 7.3L Powerstroke Diesel
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KevinsOffroad
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• Phoenix, AZ, USA |
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• Registered on 5/15/2005 |
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• 38 posts |
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Posted:6/16/2005 10:59 |
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Sounds like a plan, my friend. I'll even give you a tour of the fab shop if you're interested.
Chat soon,
Kevin
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