We are having problems with our F550 2007 Diesel, Powerstroke 6. Water in Fuel keeps coming on. Had to be towed in twice for "Water in Fuel". First time they cleaned out system. Second time replaced fuel tank. They blame all this on bad fuel. After they put the new fuel tank on and put in 10 gallons of their own "good" deisel - the light came on again. Anyone else have better ideas.

Welcome to our site, Excavating! I'm going to move this thread to the 6.0 forum where the techs as well as others are more likely to see it.

When you drain the fuel filter, are they finding water and if not, it could be a faulty water in fuel sensor....

Yes there was water in fuel and they replaced the tank because of excessive rust in tank.

The water in fuel sensor has a tendency to get corrupted by a buildup of mud and debris. Even though its drained, the sensor will stil say "water in fuel". Most generally, replacement is required. Ford terms it a Manifold.

Sounds like all the fuel where you live sucks.

blacksnapon said:

The water in fuel sensor has a tendency to get corrupted by a buildup of mud and debris. Even though its drained, the sensor will stil say "water in fuel". Most generally, replacement is required. Ford terms it a Manifold.

Click to expand...

Question for blacksnapon

OK - replacing the sensor is where Ford is headed next BUT what about the fact that the tank had to be replaced because the tank was delaminating? Isn't there a problem with the Ford tank and couldn't there be some other explanation for water getting into tank beside bad fuel. We go to a new station AND when Ford replaced the tank and put in their "good" fuel - we still got water in tank reading.

I hate to even ask this out loud, but any chance that truck's been under water?

Oh- and welcome to FTF!

No the truck has not been under water. It has normal and responsible use.

I figured that- I was thinking prior history (eg- before you bought it).

FORD: 2003-2005 Excursion
2003-2007 F-Super Duty
2004-2005 E-Series


This article supersedes TSB 06-6-5 to update the Service Procedure.

ISSUE:
Some 2003-2005 F-Super Duty vehicles built prior to 9/22/2004, 2003-2005 Excursion vehicles built prior to 1/10/2005, and 2004-2005 E-Series vehicles built prior to 9/16/2004 and equipped with a 6.0L diesel engine, may exhibit an intermittent / flickering water in fuel (WIF) lamp. The intermittent condition may be more prominent while turning corners, braking, or during uphill/downhill driving.

Some 2003-2007 F-Super Duty and 2003-2005 Excursion vehicles may exhibit a continuous WIF lamp on, even without the presence of water, due to debris in the reservoir or corrosion on the WIF sensor pins located in the manifold.

Some 2003-2007 F-Super Duty and 2003-2005 Excursion vehicles may exhibit both intermittent / flickering and continuous WIF due to corrosion and the lack of new calibration.

ACTION:
Use the following Service Procedure based upon the customers symptom.

SERVICE PROCEDURE

For intermittent / flickering WIF lamp condition reprogram the powertrain control module (PCM) to the latest calibration using the IDS release B32.11 or higher. Calibration files may also be obtained at www.motorcraft.com.
If the WIF lamp continuously illuminates without the presence of water, this may be due to corrosion on the sensor pins or sediment build up in the water reservoir.
Drain the horizontal fuel conditioning module (HFCM) reservoir and look for significant corrosion debris or sediment in the fluid drained from the reservoir. Remove the WIF sensor and inspect for corrosion on the pins. Remove the WIF Senor by first disconnecting the electrical connector, then using channel locks, rotate the WIF sensor at least 45 degrees counterclockwise. If there is corrosion / sediment on the pins, proceed to Step b. If there is not, refer to PC/ED lead diagnostics and do not proceed with the TSB.
If corrosion on the pins is causing the WIF lamp to illuminate, replace the WIF sensor with service kit, following the WIF sensor installation instructions in the kit.
If there was significant corrosion debris or sediment drained from the reservoir, clean the housing of the HFCM of any debris following the HFCM cleaning procedure. It is not necessary to replace the Manifold or HFCM assembly.
Vehicles with both an intermittent and continuous WIF light due to corrosion are to follow actions 1 and 2 as described above, referring to the vehicle built dates and application.
HFCM Cleaning Procedure

CAUTION: Smoking or an open flame of any type is prohibited when working near fuel or fuel vapor.



Disconnect both battery ground cables. Refer to Workshop Manual, Section 414-01.
Raise and support the vehicle. Refer to Workshop Manual, Section 100-02.
Disconnect the fuel pump, heater, water in fuel electrical connectors from HFCM (Figure 1).


Figure 1 - Article 06-22-12



Disconnect HFCM electrical harness from main vehicle harness.
Disconnect the fuel hoses from HFCM.
Remove the fuel hose retaining clips and discard. Disconnect the fuel hoses closest to the engine (Figure 2 Number 1).


Figure 2 - Article 06-22-12


Press in the retaining clips and release the fuel hoses closest to the fuel tank (Figure 3 Number 2).


Figure 3 - Article 06-22-12


Remove the screws and the fuel manifold cover (Figure 4).


Figure 4 - Article 06-22-12


Clean debris from the HFCM water reservoir housing (max 25 psi air).
Install the manifold cover and screws and torque to 44lb-in (5 N-m) (Figure 5).


Figure 5 - Article 06-22-12


Reconnect/reinstall fuel lines.
Verify that there are no fuel leaks from the HFCM.

PART NUMBER PART NAME
6C3Z-9C264-A WIF Snsor Kit

We replace failed WIF sensors all the time for this concern. The water in the tank could have been from the fuel, also there maybe a revised vent available for the top of the tank we had issues with these during snow allowing water in.

We bought the truck new.

You mentioned water getting into tank from snow what about lots of rain. We are in NY and in June when this became a real problem it was raining just about everyday.

excavating said:

You mentioned water getting into tank from snow what about lots of rain. We are in NY and in June when this became a real problem it was raining just about everyday.

Click to expand...

That is possible, have the dealer check the vent on top of the tank I know there was a revised vent that we were putting on the older trucks. Accually If you pm me the vin I can run it and check to see if that was available for 07.

excavating said:

Yes there was water in fuel and they replaced the tank because of excessive rust in tank.

Click to expand...

Correct me if I'm wrong, but isn't someone (dealership) blowing smoke here. I thought all of the newer trucks came with plastic tanks???? Or are they assuming that the rust is coming from the pumping source (tanks at the service station)?


My 05 PSD F250 has a plastic tank.

Well they put in a new tank last month so the new vent should be on there now in any event right?

excavating said:

Well they put in a new tank last month so the new vent should be on there now in any event right?

Click to expand...

The old parts get swaped to the new tank.