Ok, I’m pissed, Ginny’s pissed and we both have good
reason. Mind you we are not pissed at each other, we are pissed at two
different circulator pump suppliers who told us on the phone their pumps were
manufactured as replacements for the pump that just failed on our Ford Lehman
Diesel engine (after 29 years of great service).
Old Pump
|
Old Pump - Round Hole |
Such was our case on
November 7th during our pre-departure check list. Prior to getting
underway we check all engine fluid levels and seek reasons for any apparent
leaks. During our check, I found coolant in the bilge and after further
investigation it was apparent the culprit was the circulator pump. Without
being able to determine whether it was the gasket between the engine or the
shaft seal, I removed the pump for closer inspection. The evidence seemed to
point to the gasket between the engine and the pump so I cleaned the pump and
engine surfaces, cut a new gasket and remounted the pump. After adding new
coolant it was evident the culprit was the shaft seal as there was a small drip
leak from the pump weep hole.
Decision time. Replace the
pump or press in a new shaft seal and bearing. After investigating our options in
Brunswick, GA. the best option appeared to be ordering a new pump. So be it and
so it was. On Friday Nov 9th we ordered a new pump from a Georgia
based company who specializes in rebuilding Lehman Diesels. During the ordering
process they were very helpful and we were told they had replacement pumps in
stock. Due to UPS Delivery we were told it would be Monday before the pump
would be shipped with a delivery date to us on Tuesday, Nov 13th before 10:30
am. We agreed to the extra overnight shipping fees ($68) so we could make the
repair and get underway. We also ordered with the pump a “cap” to cover the
lower port on the pump. For those who don’t know, the pump was designed with
two possible hose connection ports. In the case with our engine the lower port is
not used and has to be capped. Tuesday
morning UPS delivered the package and I was stoked until I opened the package
only to discover the pump only and no cap. After the realization that the order
was incomplete and we were screwed for a next day departure I contemplated our
options.
New Pump - Not So Round Hole |
Ok, I will pull the freeze plug from the old pump and use it on the
new pump. No problem. Wrong! After inspection of the new pump I discovered the
manufacturer apparently decided to cut cost and not ream the ports so the
freeze plug from the old pump would not work. Round Peg, Square hole! Mind you
this pump cost under $200 back in 2003 when the ports were round and now has
increased to almost $500 with irregular unreemed ports.
We took the pump to a local
machine shop to determine the cost of reaming or weld the port. The estimate
was $75 to $100. I decided make my own cap by purchasing some hose , hose
clamps and a freeze plug. No problem, I will skin this cat myself. Well there
was a problem, the pump would not fit on the engine with my newly engineered
port cap. Mind you this process not only cost time, effort and money to try to
fix the problem created by shitty
manufacturing and incompetence in filling a simple order, it cost me lots of
skin off my hands and arms, head and lots of aches and pains. So the decision was made to return the pump
to the 1st supplier and order another pump from a different supplier
who told us the ports were reamed.
Fast forward two days later
when we receive the pump from the second supplier along with a freeze plug. One
problem though. The round freeze plug will not fit into the unreamed (square
hole). Same problem, different FN day. Now I’m really pissed. I call the second
supplier to discuss how they will rectify the problem since they told me the
ports were reamed. Their solution, send the pump back to them. Great ! Now we
have lost 5 freak’n days because people don’t give a crap about customer
service or making sure they actually help their customers get the right parts
to fix their problem. No wonder our country is going down the proverbial tubes.
Ok, I have a new pump that
needs a round port and the port needs to be capped. I’m not paying another $100
to ream or weld the port closed so give me Mr. Drimel, some JB Weld, a smaller
freeze plug, a rubber boot and one hose clamp please. I will fix the FN pump
myself. Minus the details, fast forward
one day and the pump has been capped and installed. In goes new coolant and no
leaks. Fantastic! Run the engine and bring it up to temperature and crap
another leak. A crack in a U-shaped hose. Drain the coolant, replace the hose
and add more coolant. Bring the engine up to temperature and crap, another
leak. This time it’s the main expansion tank lip where the pressure cap is
mounted. It has a small hairline crack. Bring out the JB Weld. Fast forward one
day and the engine is very happy. No leaks.
Lessons learned.
Always anticipate not receiving what you
order.
2
New
parts may not fit old engines or if they do, something else may have to be
modified.
3
Some people and some businesses don’t give a
crap about customer satisfaction so make sure you have good sources for your
parts.
4
Keep a good supply of JB Weld on your boat.
5
Never tell anyone the date you are shoving off
to go Cruising.
Underway on November 21st.