Studs done wo/ lifting cab, removing AC, or special tools

[BryanDowdy]

Just finished the truck. Here is a list of everything I did:

Up-pipe scoop removed
SCT tuner w/ Inn. Diesel tunes
EGR delete
Oil cooler rebuild
Cooler drain back screen
High pressure STC rebuild
High pressure stand pipe replacement
High pressure dummy plug replacement
Turbo disassemble and cleaning, inspect unison ring
Turbo drain back tube upgrade
Head inspection for cracks and warp age
Exhaust manifold gasket upgrade
Injector seal replacement
Victor head gaskets
ARP studs set to 240 ft lbs
Oil cooler rebuild


We did everything without lifting the cab or removing the AC system. We had to remove the EVAP cover, but that is it. We did not not use any special tools either. I do suggest having a bunch of different wobble joints and extensions.

After its all said and done, if you have the means to pull the cab. I would go that route. Much easier on the gut and back! It will also be much faster.

The only problem we ran into was when we started it the first time we ended up bending a push rod and break a rocker arm. This is not common, but is known to happen when the heads have sat for awhile.

It took us 2.5 days, 1 day of parts chasing, then 1 day dealing with the bent push rod. Rebuilding the oil cooler, turbo, HPOP, & fabbing the EGR delete added quite a bit of time.

Pictures: 2006 F250 - BDowdy's Photos

[BryanDowdy]

Here is a list of some of the part numbers:

8C3Z-6565-B Push rod
3C3Z-9439-AA Intake gasket
3C3Z-9229-AA Injector o-ring
4c3z-12A342-AA Glow
4c2z-12A690-AB Glow plug harness [right/left?]
4c2z-12A690-BA Glow plug harness [right/left?]
3c3z-6A642-CA Oil cooler kit
3c3z-9A375-AA Fuel line crush washers [need 6]
6E7Z-9A332-B stand-pipe kit and dummy plug
TB http://www.alliantpower.com/pdf/APTB...-watermark.pdf
W302908 dummy plug
4C3Z-9B246-E STC [Highly recommended up grade]
6C3Z-9T515-A Turbo drain tube assembly [Highly recommended up grade]
3C3Z-6C683-AB Oil cooler screen
5C4Z-9448-A Exhaust manifold gaskets [Navistar part number 1855240C1]
3C3Z-6C885-A Unison ring

[MUDSTROKIN']

Whats do you get from this? Turbo drain back tube upgrade?

[yosh30]

Great Pictures overall how hard was it? Hardest part? What book did you use to help you along the process? I saw it up on the windshield in a couple pictures

[PGreenSVT]

For all that work I would without question have pulled the motor. No way could I do all that with the engine in. They have to get a hoist to get me out of the engine compartment.

Hell of an undertaking. Good job.

[BIGG D]

On picture 17 what are you showing to the heater box? It looks like you unbolted it and slid it foward. Whats the benifit of the Onyx head gaskets also?

[MoyockPowerstroke]

Very nice...in the belly of the beast and you wern't even scared. My hero.

[BryanDowdy]

Originally Posted by MUDSTROKIN'

Whats do you get from this? Turbo drain back tube upgrade?

It is thicker and stronger than the what came in it.

Originally Posted by yosh30

Great Pictures overall how hard was it? Hardest part? What book did you use to help you along the process? I saw it up on the windshield in a couple pictures

It had its trying moments, but really its just time more than being hard. The book is the POS one from O'Reillys. It was only used for torque specs. I have instructions offline to help rebuild the HPOP. Other than that we figured it out as we went.

Originally Posted by PGreenSVT

For all that work I would without question have pulled the motor. No way could I do all that with the engine in. They have to get a hoist to get me out of the engine compartment.

Hell of an undertaking. Good job.

Yeah, if I did it again the cab would be off.

Originally Posted by BIGG D

On picture 17 what are you showing to the heater box? It looks like you unbolted it and slid it foward. Whats the benifit of the Onyx head gaskets also?

That is the EVAP cover I removed to access the head bolts. They are suppose to seal better than oem.

Originally Posted by MoyockPowerstroke

Very nice...in the belly of the beast and you wern't even scared. My hero.

Haha, thanks. Other then the bent push rod/broken rocker, it was not too scary. The HPOP is not bad, just takes time. You dont want to mess it up, will be pricey fast.

[Safety.Scott]

Thanks for the info and great pics. Geeting ready to jump in my motor too. I have been pondering to pull the cab or go at it upside down. Wonder how heavy the cab is? Can it be man handled?

[smokersteve]

Very nice! How was initial start up? And what did you do to make the initial start up go by faster and easier