My rebuild thread

[Korx]

I figured I would post up a thread to track my build/rebuild progress and so I can get advice and input along the way.

My truck is a late '04 with 160k on it with stock head bolts and gaskets with egr still in tact. My degas bottle gas been puking a little bit lately ever since I tuned my truck and smoking quite a bit on cold start. Did the pressure test for my heads/degas bottle, spiked around 17-18 psi. Bad headgaskets, or at least an excuse to do them.

First off my truck is completely stock, other than 5" exhaust, coolant filter, cts monitor, and looney fuel tuning.

Started compiling parts and a list of updated parts to order from Ford. So far the parts I have are cts, sct, egr delete, exhaust, coolant filter, and 5 gal of elc coolant.

The parts I am planning on ordering are as follows ( if anyone else needs part numbers I will post them up for you ):

Push rods
Injector o rings
ARP head studs
Fuel pressure spring
Thermostat
Updated turbo drain line
Updated turbo feed line
New glow plug harness left and right (leaking)
New oil cooler
OEM head gaskets
Dummy plugs
Turbo mounting hardware
Egr delete
Riffraff intercooler boots
Intake manifold gaskets
Exhaust manifold gaskets
Banjo Bolts
Crush Washers

I know there's probably some parts I'm missing.

Depending on funds I may try to get a set of 155s or 175s from Jesse. Not too sure about all that yet, just wanna get her goin first.

Are there any tools that will make it easier? I plan on doing this in my garage with the cab on.

How much should I budget to get my head checked/decked?


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[Korx]

Am I missing anything? Also where would the best place be to order oem parts? Trousley, Autofair, Sunrise, or somewhere else?

[southend]

Originally Posted by Korx

Am I missing anything? Also where would the best place be to order oem parts? Trousley, Autofair, Sunrise, or somewhere else?

Yes, tousley, sunrise, and i've been finding great deals on oem parts on ebay!

Sent from my phone that somebody didn't help me get.

[Tuscany]

Sunrise and Auto Fair have great deals on OEM parts. Also might want to get some wobble sockets in 1/4", 3/8" and 1/2" drive as well as a Snap-On SRD35 Head bolt adapter tool. ARP Ultra Torque Lube.

[Tuscany]

Here's a list that has part numbers and prices for all the parts listed through Sunrise.

APR Head Studs: 250-4202 - Let me know if I can help you out with these, stealth automotive $439

OEM Oil Cooler Rebuild kit: 3C3Z 6A642 CA- Order from sunrisefordparts.com $269 shipped

IPR Gen 2 EGR delete kit: SKU: EGD-60GEN2B- iprresearch.com $259.99 + shipping

IPR High Flow Coolant Filter: iprresearch.com $249.00 + shipping

Glowplug harness left side: 4C2Z 12A690 BA- sunrisefordparts.com $40.80
Glowplug harness right side: 4C2Z 12A690 AB- sunrisefordparts.com $40.80

Updated Turbo drain tube: 6C3Z 9T515 A - sunrisefordparts.com $24.37
Updated Turbo Oil feed: 3C3Z 9T516 A - sunrisefordparts.com $87.50

Thermostat: 4C4Z 8575 AA - sunrisefordparts.com $28.60

6.4 Banjo bolts: w302472 Need 2 - sunrisefordparts.com $10.50
6.4 banjo bolt washers: w303659 need 4 - sunrisefordparts.com $3.60

Main drive belt: jk8 1331 a - sunrisefordparts.com $49.82
Secondary drive belt: jk6 664 a - sunrisefordparts.com $25.34

Updated dummy plugs: w302908 - sunrisefordparts.com $24.60

OEM Head gaskets: 6C3Z 6051 AA need 2 - sunrisefordparts.com $271.20, Comes with new updated standpipe, gasket TTY headbolts and head locating dowels. Sunrisefordparts.com*

Water separator updated drain kit: 6e7z 9c082 a - sunrisefordparts.com $12.50

OEM Oil Filter: FL 2016 - sunrisefordparts.com $19.50
OEM Fuel Filter Kit: 3c3z 9n184 cb - sunrisefordparts.com $49.95

Exhaust manifold gaskets: 6c3z 9448 a need 2 - sunrisefordparts.com $21.22

CAC boots both hot and cold side. RIFFRAFFDIESEL.com I paid $140 shipped. If your cold side CAC (intercooler tube) is black plastic than upgrade to the metal one. 6c3z 6c640 aa sunrisefordparts.com $115.08

Injector o-ring kit: 3C3Z 9229 AA need 8 - sunrisefordparts.com $31.68 (if you send injectors to Jesse Warren you don’t need this part)*

Fleetgaurd Restore and Fleetgaurd Restore + cooling system chemical flushes. Can get at local big rig truck dealers (they can order it) usually around $23-$30 a gallon, need one gallon of each.

Zerex EC-1 Rated ELC fully formulated coolant, 1 case* buy it at NAPA Part number is ZXED-1 usually between $13-$20 a gallon times 6 in a case.

Rotella T6 full synthetic oil on sale at TSC (Tractor Supply Company) for $19.99 until the end of october.

I would suggest push rods since it’s apart. 8c3z 6565 b need 16- sunrisefordparts.com $64.80

ARP Ultra Torque Lube 10oz bottle with brush*

ARP 100-9910 Ultra Torque Assembly Lubricant - 10 oz. Brush Top Container : Amazon.com : Automotive

ARP 100-9910 Ultra Torque Assembly Lubricant - 10 oz. Brush Top Container : Amazon.com : Automotive

Fumoto quick drain valves for the block plugs F-108N*

Fumoto F-108N Engine Oil Drain Valve : Amazon.com : Automotive

Fumoto F-108N Engine Oil Drain Valve : Amazon.com : Automotive

Snap-on torque adapter tool for rear head bolt on driver side. SRD35 $55 + shipping

11/16 12pt 1/2” drive short socket for head stud nuts.
18mm 1/2” drive 6pt socket to remove head bolts.

Blue spring fuel pressure update: 3C3Z 9T517 AG - sunrisefordparts.com $57.60

If I forgot anything I will add it later lol.

[deesle]

Get some rocker arm clips x 2 or so for spares (super easy to break and cheap) - W302193

STC fitting update, you can do this with just taking off the turbo but if you have it all apart I think its a good idea. 4C3Z-9B246-F and ford grey sealant for cover TA31

New exhaust manifold and up-pipe bolts. W300013 x 4, W300006 x 2

Degas bottle cap - 9C3Z-8101-B

and...

Turbo recondition kit?

Also for the injector seals you may want to order the Alliant kits AP002 it includes the oil seals (I did this but it is not always necessary and it requires a surgeons hand to change them).

I agree with Tuscany on the snap on adapter. I didn't need it but having it on hand to avoid slow down can save a weekend.

Water pump, alternator, pwr steer, tensioner, idler pulley?

Just some thoughts.

[Tuscany]

Originally Posted by deesle

Get some rocker arm clips x 2 or so for spares (super easy to break and cheap) - W302193

STC fitting update, you can do this with just taking off the turbo but if you have it all apart I think its a good idea. 4C3Z-9B246-F and ford grey sealant for cover TA31

New exhaust manifold and up-pipe bolts. W300013 x 4, W300006 x 2

Degas bottle cap - 9C3Z-8101-B

and...

Turbo recondition kit?

Also for the injector seals you may want to order the Alliant kits AP002 it includes the oil seals (I did this but it is not always necessary and it requires a surgeons hand to change them).

I agree with Tuscany on the snap on adapter. I didn't need it but having it on hand to avoid slow down can save a weekend.

Water pump, alternator, pwr steer, tensioner, idler pulley?

Just some thoughts.

His truck doesn't have the STC fitting. Only 05's and up have it.

[deesle]

Originally Posted by Tuscany

His truck doesn't have the STC fitting. Only 05's and up have it.

Heh, in light of this old new information I do not recommend you do this.

[Korx]

Thank you guys both for the information.

I have been hearing about that snap on torque adapter and how exactly does that work?

Did you guys have to remove/drain the a/c in order to take the back head bolts off/torque the back head stud?

Also where can I get this head lifting bracket I have been hearing about? Is it available through Ford? I was planning on lifting my heads with a tractor as I don't have a cherry picker/ engine hoist.

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[az250diesel]

Sounds like you are in the same boat I am. Currently ordering parts for my teardown as well.
Where can I also get that head lifting bracket or something similar that would work? Will be using a cherry picker to pluck my heads out. Did you get that torque adaptor directly from Snap-on?