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You could potentially do it w/o removing the HH. The tough part is going to be the small needle in the HH that goes into the end of the actuator shaft. Unbolt the bracket (where the safety wire is) and pull straight out. The o-ring is on the shaft that slides out of the head. If the pin...

That's almost exactly how much I pulled out of mine. You can imagine the mess when my 5ga oil pan wasnt really up to the job :(. When I drained the fluid I found some suspect metal shavings, pulling the oil filters and cutting them open confirmed I had an issue. I did finally drop the pan...

Thats exactly where mine leaks from - the actuator shaft has an o-ring on the end of it. Try replacing that and see if it solves your problem. Here's the size: Actuator O-Ring: .426 x .070 = -013 or 013 (depending on which standard) Out of curiosity, how much liquid did you pull out of your...

There should be ZERO fuel behind the cutoff cable cover. When you pull it turn on the in-tank pump (but do not start the truck) and see if you see anything dripping/running at all - that's indicative of a problem.

Not sure, I haven't done it. Maybe someone who has can chime in.

The HH o-rings is a (fortunately) easy check. Did you change all 3 o-rings when you replaced the head? I've opened 2 IP's, and found the o-ring on the actuator arm to be bad on both of them, and that's an item you may not necessarily service when replacing the HH. The booster pump is on the...

Did you check the o-rings on the HH, the booster pump and the flame heater (if equipped)? Those are all possible causes of fuel in the crankcase and all seem more likely to me than a broken injector. Also, I'm not sure where a broken injector would get fuel into the oil system, you would need...