Is there anything we're missing on this rebuild? - Ford Powerstroke Diesel Forum
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post #1 of 16 Old 04-11-2011, 06:42 AM Thread Starter
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Is there anything we're missing on this rebuild?

My first Powerstroke.org post! An exciting day.

Cutting to the chase...
Truck is an 2005 F350 King Ranch dually. Truck is set up to tow, being equipped with the Tow Boss package and all the associated options, and in use, towing and plowing are its primary functions.

So, the issues. Since purchasing the truck, we've had the same issues w/ head gaskets, egr cooler/oil cooler failures, and injector failures as everyone else has experienced. The truck is out of warranty and it was time to fix it properly. The plan originally was to stud the heads, use the Victor Reinz/Black Onyx gaskets, delete the EGR system, get rid of the BS Gold Coolant, and install bypass filtration for the coolant and oil.

Upon tear down, it was discovered the heads were cracked, and as such, unusable. Add heads to the list:

Upon using Powerstroke.org as one of many research tools, many additional pieces of information came to light regarding implementing exhaust to lower EGT's, monitoring through the use of an Insight CS, tuning for the deleted EGR system, installing a CCV catch-can for the oil vapors the system induces into the intake track, and other misc. items. Here is the list of items to be installed or processes to be undertaken:
-New Heads
-ARP stud kit
-Black Onyx Gaskets
-EGR Delete
-"Hot Tanked"/cleaned intake manifold
-Silverline FS103 Turboback Exhaust (Trying to lower those EGTs)
-Complete coolant flush (Restore, Restore+, VC9, DI Water) and replacement of Gold coolant with ELC-1 coolant
-New Oil Cooler
-Updated Fuel Pressure kit (with revised blue spring)
-6.4L banjo bolts
-Bypass Oil Filtration
-CCV filter system
-Bypass coolant filter
-Insight CS monitoring w/ EGT probe, Turbo Timer, and once available, fuel pressure sensor
-SCT Tuning for EGR delete, etc.

Now that this info is clear, I'm faced with a final question: Is there anything I'm overlooking? What, if anything, about this "bulletproofing" approach falls short of making the engine as reliable as possible?

I need this truck to make me money. I have gotten just shy of 100k miles without any major issues (warranty issues aside), other than routine maintenance. I'd like to go 200k more without having to go through the suffering and money spending this current process involves.

So...I'm all ears, Powerstroke guru's. What are your thoughts?

Here's some pics of the current state of affairs of the truck for your viewing pleasure.



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post #2 of 16 Old 04-11-2011, 06:58 AM
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i dont have any other ideas, but i want to say welcome to the forum and good luck with the build!

2003 F-250 6.0 ECLB- [B]
-EGR Delete-Oil cooler-6.4 Banjo Bolts-WW2-turbo feed and drain lines-upgraded alternator-upgraded FICM

Previous trucks: 1997 F-350 CCLB, 2000 F-350 CCLB, 2008 F-250 CCLB
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post #3 of 16 Old 04-11-2011, 06:59 AM Thread Starter
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Originally Posted by lhsnbsaoa View Post
i dont have any other ideas, but i want to say welcome to the forum and good luck with the build!
Appreciate it!

Only thing I can think of, having looked at the pictures again, is getting something along the lines of POR-15 and getting the frame rails looking nice and black.
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post #4 of 16 Old 04-11-2011, 07:06 AM
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I would replace the oil cooler while you're in there. Other than that, I think you have all the bases covered



EDIT: the oil cooler is already on the list


2006 F350 SOLD
* KMC XD Monsters wrapped in Hankook ATM's
* 08 style mirrors
* 4" TB exhaust
* SCT X2 with Gearhead, PHP and ID tunes
* Edge Insight CTS
*Full Bulletproof Diesel kit with remote oil cooler
* Blue FPR spring
* 6.4 Banjos
* Repaired FICM by BPD
* Dfuser coolant filter
* Stage1 MTW turbo



New truck has a Cummins and a handshaker
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post #5 of 16 Old 04-11-2011, 07:08 AM Thread Starter
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Originally Posted by 2006PSDSD View Post
I would replace the oil cooler while you're in there. Other than that, I think you have all the bases covered



EDIT: the oil cooler is already on the list
Yep. That's on the aforementioned list!
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post #6 of 16 Old 04-11-2011, 07:11 AM
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I think you have a good handle on it then bud


2006 F350 SOLD
* KMC XD Monsters wrapped in Hankook ATM's
* 08 style mirrors
* 4" TB exhaust
* SCT X2 with Gearhead, PHP and ID tunes
* Edge Insight CTS
*Full Bulletproof Diesel kit with remote oil cooler
* Blue FPR spring
* 6.4 Banjos
* Repaired FICM by BPD
* Dfuser coolant filter
* Stage1 MTW turbo



New truck has a Cummins and a handshaker
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post #7 of 16 Old 04-11-2011, 07:29 AM
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i took the pedistal off the top of mine just so i can clean the engine a litttle better on top to make it nice and pretty

ASE Master Certified Technician
04 Powerstroke lovin it
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post #8 of 16 Old 04-11-2011, 08:38 AM
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STC fitting done? Might want to hit that while its torn down like that if it hasn't been addressed.
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post #9 of 16 Old 04-11-2011, 05:07 PM Thread Starter
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Originally Posted by NYC F-350 View Post
STC fitting done? Might want to hit that while its torn down like that if it hasn't been addressed.
It will be done, regardless. Anything else? Night crew?
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post #10 of 16 Old 04-11-2011, 05:16 PM
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stand pipes and dummy plugs in the high pressure oil rails
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