WW, foil delete, glow plugs, up pipes, write up.
Its long but a good read.
Well this past week (end) I changed out a handful of parts on my truck, a 2000 CC PSD with 170k miles. Wicked wheel to get rid of turbo surge, glow plugs and I replaced my up pipes and new Chevy doughnut gaskets, I also removed the foil from the intercooler tube.
A few things to note during this process. The wicked wheel does produce more noise, I don’t mind it, its definitely very high pitched. Be careful removing the foil on the intercooler tube. That crap is sharp and will cut you…..a few times. I used a wire wheel, it worked pretty well to remove the adheasive. Glow plugs were easy to install, I went ahead ohmed my old ones out once they were removed. All of them were open/bad; no wonder that thing wouldn’t start. Once I did started the truck you could hear the GPR “click” like it had never clicked before you could also see the amp meter drop a little from the glow plugs actually pulling some current. The truck started right up.
Now for the fun part, replacing the up pipes and gaskets. I knew I had a pretty bad exhaust leak thanks to my bad glow plugs. Whenever I had to start the truck cold there was smoke blowing everywhere under the hood. I had a buddy look and he could see the smoke coming from the up pipe 2 to 1 collector (not sure of the real name of the 2 to 1 pipe). Sitting in traffic I could also smell exhaust in the cab. Once I removed the turbo I went ahead and grabbed the 2 into 1 collector that attaches to the turbo. It was very very lose. Clearly that was not sealing. So I removed the 2 to 1 and could tell that my up pipes were much worn. I bought new up pipes, bolts and the Chevy doughnut seals. I put the new up pipes on the truck loosely. I then put the new Ford bolts and Chevy doughnuts on the 2 to 1 collector and slid them over each up pipe. Put turbo back in place and then aligned the 2 to 1 to the turbo (this part sucked for me). Once up top was snugged up and in place I went under the truck to get to the bolts from below. I seated the up pipes to exhaust manifolds (easy) and with about 3 feet in extensions I started tightening the up pipes at the 2 to 1 collector. ALL WAS GOING WELL THEN ONE OF THE FORD BOLTS STRIPPE3D OUT ABOUT 3/8 INCHES OF THREAD IN MY 2 TO 1 COLLECTOR!!!!!!!!!! I was so pissed/bummed out; I knew something had to go wrong. I should have noticed this before that the Chevy doughnuts are significantly thicker that the ford doughnuts. So some food for thought, get new and LONGER bolts if you use the Chevy doughnuts. I didn’t read anywhere online that anyone else had this problem. Maybe it was just poor casting in my 2 to 1 collector. Went to NAPA bought a longer bolt, put it in and prayed that it would snug up. It did. So put everything back together and took the truck for a spin…..ITS A WHOLE NEW TRUCK. I have all my low end torque back. I think I was losing a good amount of boost due to my huge exhaust leak and im hoping for better MPG’s. It’s no longer a dog off the line. Many people say you can see soot around your up pipes and know you have a leak. Well I didn’t have any noticeable soot as my truck doesn’t blow a ton of smoke unless im towing. So maybe on a cold day, disconnect the ACC switch power to your GPR, crank it over a few times and see if you get any smoke under the hood. If you do, it might be time to change your up pipes and gaskets.
That’s all I have for now.