Project Mayhem - A Build Thread - Ford Powerstroke Diesel Forum
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post #1 of 95 Old 03-25-2017, 05:56 PM Thread Starter
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Project Mayhem - A Build Thread

Hello everyone, PSD newb here, but jumping in with both feet. By posting this thread, I wanted to introduce myself to both contribute to the forum by way of pictures and experience, but also to gain advice for repairs and modifications. With that out of the way, on to the story.

Bought a 2004 F550 (1FDAW56P84ED64322) in Dallas last summer with ~210k miles and drove it back to Durham, NC. Clean carfax, no bed, white (the best color), vinyl interior, ZF-6 transmission. I'm a huge fan of the truck but it has it's fair share of problems. As I learned more about the motor and how to monitor it properly, I learned that the head gaskets were bad. The truck already had an EGR delete and possibly a tune.

Took the plunge today and pulled the cab off so I can do the engine work and some other modifications to prepare for this year's wheeling season. Plan is to put studs in with OEM gaskets, possibly o-ring the head (not positive on that yet, still researching), new OEM oil cooler, Fumoto coolant drain valves, 6.4 starter, new glow plugs, rebuilt injectors, new stand pipes/dummy plugs, new glow plug and injector harnesses, and the list continues. For the body, I'm going to coat the bottom in a lizard skin type product to improve sound deadening. Likely the firewall as well. Frame will be painted with something along the lines of POR15 to help preserve it.

I'll either make or buy a steel flat bed for the truck with a gooseneck hitch to tow my Land Cruiser around!

Excited to be here and excited to have a well running 6.0!!

On the way home:



Did the blue spring upgrade a while back:



How she was for a while:



We have separation!



Fairly certain that the 550 rolling chassis weighed more than my buddy's Duramax



More to come.

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2004 - F-550 Crew Cab ZF-6

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post #2 of 95 Old 03-28-2017, 05:50 AM Thread Starter
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Before pressure washing:



After:





Still trying to figure out if this is an early or a late engine. I'm leaning towards late due to the IPR sensor being in the PS valve cover, but I'm not sure if that's a definite measure. Oil rails should tell me.

Found some interesting stickers under the grime. Was hoping the engine serial number would tell me but I can't figure out how to look up any info on this motor by serial number. Cummins makes this easy with QuickServe. Do we have an equivalent?






At about 23' overall length, this thing barely fits in the garage!! I plan to have the tear down done tonight:

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2004 - F-550 Crew Cab ZF-6

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post #3 of 95 Old 03-28-2017, 06:27 AM
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Hey looks great, got any pics of the Land Cruiser?

New owner of "Buford".
2011 F250 Crew Cab 4x4 6.7 Lariat

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post #4 of 95 Old 03-28-2017, 09:31 AM Thread Starter
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Your location is Fort Worth! I bought this F550 from a dealer in Lake Worth. Small world

I have hundreds of pictures of my Land Cruiser. Here's one from this past November at the Outer Banks in NC.

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2004 - F-550 Crew Cab ZF-6

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post #5 of 95 Old 03-28-2017, 09:41 AM
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Welcome to the forum! Seems your off to a great start. Good luck!


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post #6 of 95 Old 03-28-2017, 12:16 PM
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Quote:
Originally Posted by GLTHFJ60 View Post
Your location is Fort Worth!
I bought this F550 from a dealer in Lake Worth.
Small world

I have hundreds of pictures of my Land Cruiser. Here's one from this past November at the Outer Banks in NC.
Nice rig! I'm a huge Toyota 4x4 fan. Especially the FJ60.

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New owner of "Buford".
2011 F250 Crew Cab 4x4 6.7 Lariat

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Last edited by SixFive; 03-28-2017 at 12:22 PM.
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post #7 of 95 Old 03-28-2017, 03:02 PM
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Man absolutely love old LC's and FJ's . Beautiful truck

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post #8 of 95 Old 03-29-2017, 06:57 AM Thread Starter
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Thanks guys. This F550 will tow my Land Cruiser, affectionately named Moonshine, all around the country. I plan to pick up a ~42' gooseneck to make a redneck crawler hauler.

Got my 6.0 torn down last night and it looks good! Block is perfectly fine, no water jacket corrosion. I saw a few spots on the MLS head gaskets that could have been the HG leak, but it's hard to tell and the leak could have been inbetween the layers as well. Like a dope, I didn't get any close-up pictures of the block mating surface, but I did get pictures of a few cylinders showing the cross-hatch marks from the last time it was honed. I love diesel engines. Block is certified good to go :bounce:

This thing has definitely been apart before, based on the EGR delete, updated stand pipes, updated oil feed and drain lines, newer glow plugs, etc. It's been a while though, found a broken injector connector, a few broken glow plug connectors, harness not restrained in the head in a few places, etc. If the head gaskets have been replaced once, I'm assuming it was years ago and was likely at a dealer, because all the right updated parts were used but they used head bolts instead of upgrading to ARP studs.

Other oddities, this engine has the later style ICP sensor on the injector oil rail, has the later style fuel regulator, later style injector oil rails, later style glow plugs and pistons, but has the early style HPOP and also has the EGR throttle plate. Doesn't make sense.

I also plan to delete the second alternator because it's cheaper to do that than to buy a new serpentine belt for it

Either way, will get my parts order together, get these heads off to be reworked and send the injectors off for servicing. Would appreciate advice on this list to make sure I'm not missing anything. I spent a number of hours reading all of the FAQs and build threads, so I think this is all I need, but I would love for a few ORG members to double-check:

Amazon:
Fumoto F108N for coolant block drains
250-4202 -ARP Head Studs
100-9910 -ARP assembly lubricant
ZXED1 Concentrate coolant
6c3z 9448(x2) - exhaust manifold gaskets
W302472(x2) W303659(x4) - 6.4 banjo bolts and washers
3C3Z-9H529-A -IPR screen
w302908(x2) -dummy plugs
3C3Z-9T514-AG - Turbo mounting hardware
3C3Z 6051 CB(x2) -Head gaskets (with updated stand pipes)
4C3Z 12A342 AA(x8) -glow plugs
4C2Z 12A690 BA and 4C2Z 12A690 AB-glow plug harness
6C3Z8A080B - dgas bottle
4C4Z 8575 AA - Thermostat
6.4 starter
Royal Purple Synthetic ATF for the ZF-6
new DGAS bottle
new AC Drier

Not necessary but "while I'm in there":

MRBP FAL2313 Turbo up pipe (truck has stock up-pipe)
MBRP S6240AL full turbo-back exhaust
Banks 42751 High-Ram Intake System (to eliminate the EGR throttle plate)

From iprresearch.com
3rd gen EGR delete kit - comes with the following
- 3C3Z-6A642-CA -Oil cooler and o-rings/gaskets/screen
- 3C3Z-9433-BE -Intake manifold gaskets
new coolant full flow filter
(maybe) turbo unison ring
(maybe) compressor housing o-ring



In thanks for the parts list advice, here are copious tear-down pics:



What is the name for the rubber hose attached to the intake manifold in the below pic? It tore on disassembly so it will need to be replaced.



















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2004 - F-550 Crew Cab ZF-6

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Last edited by GLTHFJ60; 03-29-2017 at 07:12 AM.
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post #9 of 95 Old 03-29-2017, 07:45 AM
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Awesome photos, thanks for sharing!

That would freak me out having my truck torn apart like that!

LOL

New owner of "Buford".
2011 F250 Crew Cab 4x4 6.7 Lariat

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post #10 of 95 Old 03-29-2017, 09:14 AM
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Nice job and

If it was my rig and I was spending that much time and money, I would go with a set of UCF O-ringed heads. Done once and for all. just my

Keep up with the pics because this thread would be worthless without pics!

Zach

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6000K HIDs, Fog mod/High Idle, Tinted,
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138,000 miles....
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