Ford's answers to the NHTSA 6.7 Investigation

BenK wrote:

In narrowing this down, ask why the previous pump did not have this
issue, that we know of.

Cavitation is my #1 and am getting more and more confident that it is
with the comments of 'timing' of the pump to the injectors...which to
me is purely missing the boat, as how do you time 8 pulses that are
random to the pump, which has one, maybe two pistons. Do the matrix
of how you can time those two pulses and the complexity of the controller
and sensors to time them.

Both the mechanical and electronics needed to do that (I'm not sure it
is even possible no matter how much money you throw at this).

Find that there was a gear pump and was my first solution to this whole
mess.

Another point is that there are well known solutions to the cam/roller
contact PSI problem. That is to reduce the PSI. That then says to both
increase the dia of the contacting components and/or increase the width,
thereby increasing the surface area, thereby reducing the PSI

Am satiated enough to say it is in the pump and at either/or both the
cam/follower and piston/cylinder.Another point is that there are well known solutions to the cam/roller
contact PSI problem. That is to reduce the PSI. That then says to both
increase the dia of the contacting components and/or increase the width,
thereby increasing the surface area, thereby reducing the PSI

Am satiated enough to say it is in the pump and at either/or both the
cam/follower and piston/cylinder.

Am thinking truly penny wise, pound foolishness in trying to keep the
same pump, and/or form factor that they have overly band aided the heck
out of it. To the point that they have dug a hole so deep that they
are now working at adding width to that hole.

That is in light of the cam shaft bearing and it's seal. If there is
such a severe condition in there that they have to go to the measures
they have to excise H2O and the exotic (expensive) plating that they
may have missed yet another source of H2O...that cam shaft bearing seal(s). Plural, as there should be a min of two for any shaft of that
architecture

Repeat that I'm not a diesel guy, but am a long time designer and know
that all designers LOVE far out stuff. The more exotic it is, the more
fun there for the designers...but...too often designers and teams get
lost in these rat holes

Key is to have someone with the ability to bring them back up to the
big picture and is where I think they have failed to do and continue
to band-aid over band-aid over band-aid with their CUSTOMER (therefore
reputation) taking it on the chin or shorts.

I have discussed this on TDI club over a year ago, wider cam, bigger diameter roller, bigger piston, to lessen the psi load where the cam meets the roller, as well as being wider, providing more alignment surface between roller and cam, and preventing piston rotation.