My first injection pump failure happened three and a half years ago, on a very hot August day in Phoenix. I was returning home from from Tucson, and made it almost all the way before the truck died. Luckily, I was only 1/4 from my driveway. I noticed about halfway home, the truck did not have much power, and I had to mash my right foot to the floor to maintain 65 MPH. At the last few stop lights, the truck would not idle. The truck had 152K on the odometer at the time. When the truck died, the engine seemed to crank at a much higher RPM with the starter. Other than the symptoms just before it died that day, I had no other warning of approaching pump failure.
My second Injector pump failed at 194K, just over a year and a half ago. Again no warning signs of approaching pump failure. Luckily, it failed in my driveway and once again I did not have to pay the tow truck driver. Both times when the pumps were overhauled, the Bosch overhaulers claimed dried seals to be the primary cause of failure. My first overhaul lasted only 42K mi, and less than two years. I don't know if high engine compartment temperatures contributed to such a short pump life, or maybe just a bad overhaul. Anyway, I did not take it back to them for the second overhaul, and consider myself fortunate for not having it fail in the middle of nowhere.
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89 D-250 LE 5 speed 3. 55 Limited slip, K&N, straight piped, Boost/Pyro. & 16cm2 215K and still going. 91 W-250 5 speed, 4. 10 Limited slip, 16cm2, 6" Skyjacker lift, RS9000, Dump bed, 18K original mi.
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