My Poor Truck . . .
 

Currently the Truckinator is down and out. Replaced the water pump so far with the Bullet Proof Diesel upgraded one. Now onto replacing the blown EGR Cooler with a Bullet Proof Diesel one - and replacing the Oil Cooler. In addition to replacing a hand full of various other parts while I have it apart. The turbo will get replaced with a Stage One turbo which will better handle the extra HP the Quadzilla chip is pushing out.

Tomorrow will work on getting the intake manifold and injector harness and junk out of the way so I can get to the EGR cooler. Fun stuff huh.

So - down and out at the moment but should be back better and stronger in a few weeks.

Before starting:
http://www.dgdesigns.com/humidor/EGR...cn0904_std.jpg

Current view:
http://www.dgdesigns.com/humidor/EGR...cn0916_std.jpg

What I'm trying to get to:
http://www.dgdesigns.com/humidor/EGR...n0920a_std.jpg


All Of The Pictures

Ron

Re: My Poor Truck . . .
 

Looks like you have your hands full. Good luck brother!!!

Re: My Poor Truck . . .
 

That doesn't look fun at all. Good luck.

Re: My Poor Truck . . .
 

Ouch!!

Re: My Poor Truck . . .
 

Have fun with that. I hope it works like it's supposed to.

Re: My Poor Truck . . .
 

Sadness is a sick truck :)

Re: My Poor Truck . . .
 

no,sadness is getting up under the hood to get to all that :td

Re: My Poor Truck . . .
 

I know your pain. On my way back from my inlaws, the front differential and/or the Transfer case on my truck let go. Fortunately, I run a shop so I have the equipement to fix it. good luck on your repair. if you need some info, shoot me a pm

Re: My Poor Truck . . .
 

Touché'

Re: My Poor Truck . . .
 

Theres an engine under all that crap??? Makes me glad I have the 5.9 in mine.

Re: My Poor Truck . . .
 

Good Luck Brother...I feel for ya

Re: My Poor Truck . . .
 

Yeah, I don't think my back can handle hours under the hood anymore. :D

Re: My Poor Truck . . .
 

Man, I know that cannot be good, but I look at that and see/hear metal and moving parts.... It makes sense to someone, just not me....:r

Best of luck getting her back on the road.....

It's all ball bearings nowadays. Now you prepare that Fetzer valve with some 3-in-1 oil and some gauze pads. And I'm gonna need 'bout ten quarts of anti-freeze, preferably Prestone. No, no make that Quaker State.

Re: My Poor Truck . . .
 

How hard is it to pull the turbo? EGR on a diesel is stupid. The amount of problems it causes is not worth the small amount of emissions reduction. It really complicates the intake system and engine computer programming. EGR coolers will always be a regular maintenance item. I had a shop clean mine last time but I will replace it next time it gets clogged.
Show more pictures, please.
Beware, too much power puts a strain on the head gaskets. Ford already took the Navistar design and pushed it to the safe limits. Some would say they pushed it too far.

Re: My Poor Truck . . .
 

The actual art of removing the turbo isn't hard at all. It's only held in by three 10mm bolts. Or in the case of my truck - two bolts as one backed itself out and I found it in the valley. The hard part is removing everything just to get to the turbo. Most shops though will simply lift the whole cab off the truck.

Agreed - EGRs on a diesel is and always will be a stupid idea. Mine was replaced twice under warranty and I cleaned it once. I will be installing a brand new one this time around.

See below - :D

Currently I am hoping the head gaskets are okay. It overheated big time when the water pump went out. I have none of the classic signs of a blown gasket so fingers crossed.

As for the extra power - she has 160,000 miles at the moment and has had the power since mile 28. :D

To see all the pictures I have taken - click the link. I'm taking these pictures to help remind me of what goes where when I put her back together.

LINK TO ALL THE PICTURES HERE

And this is what she looked like at the end of today. And oh - for those who don't know, this is a 2004 F350 6.0L King Ranch FX4

Ron

http://www.dgdesigns.com/humidor/EGR...cn0933_std.jpg

Re: My Poor Truck . . .
 

Looks like your dinner place settings are well done, Ron.
Indeed, there is nothing like being elbows deep, and bloody knuckled to appreciate how packed in all these components are in a modern engine.

Re: My Poor Truck . . .
 

Uh-huh - you know damn good and well that if I don't put the napkins out I'll end up dropping something down the intakes or HPOP. Just my luck -


Ron

Re: My Poor Truck . . .
 

I love that Bullet Proof website. I think I'll get one of their EGR coolers next time.
The overhead creeper for working on tall vehicles they sell is a great idea. A bit pricey, though.
On the oil cooler:
Air is much worse than water for carrying heat away. They seem to make up for it by making it much larger. I would prefer a combined solution, the way transmissions are cooled. Run the oil line through the radiator first, then through a smaller air cooled cooler. There's already four radiators in the front of these trucks. A/C, engine coolant, turbo intercooler, and transmission oil cooler.

Re: My Poor Truck . . .
 

Yeah - the EGR cooler is an excellent design. I don't see it busting anytime soon. Overall it's a great site - but like any site you have to watch things. I decided yesterday to replace the IPR screen and seals. Dealer wants $60 - they have it for $53. But when I added it to the cart the cheapest shipping was for like $23. We are talking about a screen slightly larger than a quarter and two o-rings. Found the Ford kit on Ebay for $36 with shipping included. Should be here Thursday.


I went with the EGR Cooler Kit that includes all the gaskets and stock oil cooler rebuild. The money they wanted for their aftermarket kit was well over my budget plus as you say it's air cooled. I'd like to see them come up with an oil cooler that fits the stock area but built like their EGR cooler. That would solve a boat load of problems.

No work on the truck until Friday at the earliest - I don't have a garage unfortunately - :(
Might get to the oil cooler rebuild Wednesday evening.


Ron

Re: My Poor Truck . . .
 

Somewhat productive weekend. Starting to put her back together now. Took Friday and Saturday though to get the intake manifold cleaned out of the soot and carbon build up. 5 cans of engine degrease and a pressure washer finally got it.

Anyway - here are some pictures. All of the picture to date: Click Here

Ron

http://www.dgdesigns.com/humidor/EGR...cn0934_std.jpg

http://www.dgdesigns.com/humidor/EGR...cn0936_std.jpg

http://www.dgdesigns.com/humidor/EGR...cn0939_std.jpg

http://www.dgdesigns.com/humidor/EGR...cn0943_std.jpg

http://www.dgdesigns.com/humidor/EGR...cn0945_std.jpg

Re: My Poor Truck . . .
 

If you need any help just PM me I will send you my number. I am a owner of a race team so I can get you parts a wholesale.

Re: My Poor Truck . . .
 

Wow, nice offer brother. :l

Re: My Poor Truck . . .
 

Almost done?

Re: My Poor Truck . . .
 

How's the truck Ron? Looks like a mess and unfortunately I do not know much about auto mechanics.

Re: My Poor Truck . . .
 

Hey Thanks for the offer. I pretty much have everything I need at the moment or it's already been ordered. But I may be needing a new torque converter in the future that will handle the little extra power I have (Quadzilla Chip).

Ron

Re: My Poor Truck . . .
 

Not done but it's coming along. Have to concentrate on other things for Christmas. Plus the wife wasn't happy with the mini portable garage I built over the front of it to work under with Christmas coming.

Here are a few picks of how it looks at the moment. She has had a bath (pressure washed), new hoses, new belts, new solid stainless steel fuel line, re-wrapping the wire harness(s) and other stuff. At this point just going over everything with a fine tooth comb. Cleaned every electrical connection and applied die-electric grease.

After the holidays will get back to her.

Ron


http://www.dgdesigns.com/humidor/capics/DSCN0952a.jpg

http://www.dgdesigns.com/humidor/capics/DSCN0953a.jpg

Re: My Poor Truck . . .
 

Well finally got her back together and running earlier this week. Here is the before picture:

http://www.dgdesigns.com/humidor/EGROIL/Before.jpg

Here is a list of pretty much everything that I did that I can think of:

01. Replace engine oil cooler.
02. Replace EGR cooler.
03. Replace EGR valve.
04. Rebuild IPR (Injector Pressure Regulator)
05. Rebuild fuel regulator with 65psi spring.
06. Clean carbon from intake manifold.
07. Install new intake manifold gaskets.
08. Replace turbo with Garrett stage one turbo.
09. Replace turbo electrical connector.
10. Replace flex turbo oil feed line with solid oil feed line.
11. Replace turbo oil drain line.
12. Replace air intake with Injen Intake System.
13. Replace intercooler tube with new non-crimped tube.
14. Replace intercooler boots with silicone boots.
15. Replace all filters, oil, both fuel, inline trans, bypass trans.
16. Install new drive belts.
17. Re-wrap all electrical lines.
18. Replace all wire ties and heat shields.
19. Replace upper and lower radiator hoses.
20. Replace thermostat.
21. Replace boost gauge line.
22. Clean all electrical connections and re-grease.
23. Integrate Quadzilla 165HP chip wiring better.
24. Change oil.
25. Replace steering pump oil.
26. Flush coolant system.
27. Flush transmission fluid.
28. Clean and pressure wash engine and compartment.
29. Replace driver’s seat heaters.
30. Sent Valentine One in for latest updates.

And here is the after picture:

http://www.dgdesigns.com/humidor/EGROIL/After.jpg

Aside from breaking the stupid plastic nipple for a return line on the radiator - it all went well - no left over parts that were not supposed to be - :D

Ron

Re: My Poor Truck . . .
 

That thing looks awesome. Great work.

Re: My Poor Truck . . .
 

Great job, Ron...Congrats! :tu

Re: My Poor Truck . . .
 

Looks great! Now take it out an enjoy it :)

Re: My Poor Truck . . .
 

My daughter says your truck looks like Optimus Prime now. Congrats!

Re: My Poor Truck . . .
 

Damn fine job!

Re: My Poor Truck . . .
 

Looks great! So about my truck....


:)

Re: My Poor Truck . . .
 

Got any pictures of the whole thing? I love Ford Diesels.

Re: My Poor Truck . . .
 

Power Strokes usually don’t F--K-UP have you ruled out that your Chevy buddies dint sabotage you. LOL

Looks good!

Re: My Poor Truck . . .
 

Wow, great job:tu

Re: My Poor Truck . . .
 

Nice to see someone who knows what he's doing! Hindsight being what it is, I'd have been better off going into auto mechanics than liberal arts!

Re: My Poor Truck . . .
 

unless it's the 6.0.......:hn

Re: My Poor Truck . . .
 

Yea I can’t believe they kept them around for 5 years!! They cost the Ford millions $$$

Re: My Poor Truck . . .
 

Where and when I grew up almost every teenaged boy "went into" auto mechanics. Some made it their profession.

I have the 6.0 and I thought it was a lemon at first but now that the issues with it are known you can stay ahead of them and keep the engine running fine like the awesome powerhouse that it is. I can pass semis on the freeway while towing my trailer uphill at 80 mph. And mine is stock.

Re: My Poor Truck . . .
 

Here are a few pics - 2004 F350 King Ranch 4x4 FX4

Ron

http://www.dgdesigns.com/humidor/capics/04F3504a.jpg

Re: My Poor Truck . . .
 

I like the way your daughter thinks - :tu

I nicknamed name her the Double Helix way back - but to others she has been known as the Truckinator - :D

Ron

Re: My Poor Truck . . .
 

My boss is a Chevy man - but unlike him I have pictures of me towing his Chevy's to the dealer for repairs!

I went 98K+ miles on this 6.0 with no problems. And that is with a 165HP race chip in her from mile 28. That's how many miles it took me to get her home. At 98K+ the Ford dealer replaced the EGR cooler under warranty and it's been this and that minor problem since then.

Now she is running the best ever. I have blown the tube from the intercooler to the intake off three times this week - so I guess I will have to spend a few bucks and get the upgraded metal tube with silicone boots. The stock one is plastic.

Other than that I'm a happy camper - :ss

Ron

Re: My Poor Truck . . .
 

That's a great looking truck.

Re: My Poor Truck . . .
 

Clean the joint on the intercooler tubes and apply hair spray. The stock ones come with a tacky substance on them that only works once.

Re: My Poor Truck . . .
 

Thanks for the tip - didn't think of that. When I bought the silicone boots for the other side they came as a set of four. Was looking today to see if I couldn't fit one over the stock tube.

Ron