Warning to Diesel Fuel Tow Vehicle Owners

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TucsonJim

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Feb 6, 2014
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Please learn from my mistake. Yesterday, I accidently put 2-3 cups of Diesel Exhaust Fluid into the diesel tank instead of the DEF tank. Bottom line result. The truck is at the dealer now and the damage appears to be somewhere between $12K to $14K. I filed a claim with my automobile insurance policy, but I'm not certain they'll cover it.

Jim
 
Another reason to own a pre-emissions truck!! (or delete the emissions afterwards!)
 
Hey Jim, you aren't the first and probably won't be the last to make a mistake like that. Sorry it's going to cost so much.
 
TucsonJim said:
Please learn from my mistake. Yesterday, I accidently put 2-3 cups of Diesel Exhaust Fluid into the diesel tank instead of the DEF tank. Bottom line result. The truck is at the dealer now and the damage appears to be somewhere between $12K to $14K. I filed a claim with my automobile insurance policy, but I'm not certain they'll cover it.

Jim
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What all is being replaced for $12K!!!!!
If you trashed all injectors (which I find hard to believe) and replaced w/ hi perf at 500@ = $4k
New CP4 Injector pump for under $2k
Drop tank and flush
12 hrs labor @ 150 per = $1800
I don't like the math. I would really question what they are doing.
I am not a Ford guy, but I am sure you are not the first person to do this.
I would go to the Powerstroke Forum and ask questions. http://www.powerstroke.org/forum/ford-powerstroke-scorpion-6-7-2011-forums/
 
That does seem extremely expensive. Can't imagine why it would be that high.
 
Most issues of this nature require the high pressure fuel pump and all its associated plumbing to be replaced. Cause, no lubrication causes destruction of the high pressure fuel pump which contaminates the system from this point on. Many small metal flakes abound. Talked about at length on all forums where fuel contamination occurs, mostly from external fuel tanks that don't seal well enough to keep out water. But just what is DEF?, mostly water. If you start your motor and run it, makes no difference how long, many dollars to repair. If you did not start the motor and had it towed to shop, just drop tank, flush out entire fuel system/tank, reinstall. Know this does not help your situation, but for all of us that have vehicles that use DEF, it is something I always look at when filling. Also, mixing gasoline to diesel fuel is bad and causes the exact same results. This issue has become so bad, that one manufacturer, VW (I also own a TDI) issued a service notification to install a part that makes a gasoline nozzle not open a flap valve, so you can't put gasoline into the tank. Diesel nozzles are suppose to be bigger, but I refused this as some stations use same size for all pumps.. I have been putting diesel into vehicles since early 2000, so far my luck holds. Now, throw some salt over my shoulder, knock on wood, rub a rabbits foot, and make a wish so my luck holds. :D
 
Sorry to hear this, they never get BETTER just worse when building these things. I have the 2012 Ram Laramie Longhorn which does not have the DEF thank goodness. It's a nice ride but a diesel hog unlike my 2004 5.9 HO. I have owned 3 and my oldest diesel was the best. As soon as my warranty runs out I'm taking it to St. Joe Diesel and having all that crap taken off and chipped for gas mileage . I hope things get better for you, oh shop around dealers are always the most important.
 
It's not just the injectors and fuel pump. It's all the lines, filters, dfcm, sensors, injectors, upper and lower fuel manifolds, injectors and pump. In addition, the tank has to be dropped, flushed and dried. There is a Ford Service bulletin that states the exact steps to resolve the issue and restore the warranty. Unfortunately, I ran the truck for about five miles before the system started to act up.

It's not the water in DEF so much as the Urea. It forms crystals which contaminate the entire system. Fail to take all the steps above, and the crystals will form on the injector tips. If one injector locks open, it will flood the cylinder with diesel fuel and cause the engine to hydrolock. If that happens, it's a catastrophic engine repair or replacement too, and the price skyrockets another several thousand dollars.
 
That really sucks man, sorry.

Unless AZ insurance is different than Texas I don't think there will be any insurance coverage.
 
Just got a call from my insurance company. I'm covered! $500 deductible. Should have the truck up and running by Friday or Monday.
 
That's great news for you about the Insurance. I am back to running diesels after a 6 year break. Now I have one with DEF and I am unsure if I like the idea. A questions for those of you with experance, How often do I need to fill the DEF tank?
 
Hey Jim, who is your insurance company? I'm calling them tomorrow! Seriously, who is it?
 
KZ,
My F350 has a 5 gallon DEF tank and is good for about 4000-5000 miles, depending on driving conditions. I'm sure there are some Chevy folks out there that can give a better estimate for your truck.

BTW. That's AWESOME the insurance covered it!
 
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