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Old 01-01-2013, 05:05 PM
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Bulletproofing my 6 Liter

I finally got all my parts in and got the time to start bulletproofing my 6.0. Only problem is that it's winter around here and my garage isn't heated, and my 6.0 hardly fits!

Plans are a whole slew of updated/oem parts, arp's, egr delete, all the typical stuff basically.

Here's my shopping list for anyone who's interested. My truck is a late '04.

1x - Oil Cooler - 3C3Z 6A642 CA
1x - Updated Turbo Oil Feel Line - 3C3Z-9T516-A
1x - Updated Fuel Supply Tube - 6E7Z-9A332-B
2x - Head Gaskets (with standpipes?) - 4C3Z 6051 EB
8x - Fuel Injector O-Rings - 3C3Z 9229 AA
2x - Exhaust Manifold Gaskets - 6c3z 9448 a
2x - 6.4 Banjo Bolts - w302472
4x - Copper Washer for Banjos - w303659
1x(not sure?) - Dummy Plugs - w302908
3x - Rocker Arm Clips (just in case) - W302193
4x - Up Pipe Bolts - W300013
2x - Y-Pipe Bolts? - W300006
16x - Valve Push Rods - 8c3z 6565 b
1x - CCV O-ring (green - lost mine) - W302725
1x - Thermostat - RT-1169
1x - Intake Manifold Gasket (is it a set? Left and right the same?) - 3C3Z 9439 AA
1x - Glow Plug Harness Drivers - 4C2Z 12A690 AB
1x - Glow Plug Harness Pass - 4C2Z 12A690 BA
1x - Fuel Pressure Spring Update "Blue Spring" - 3C3Z 9T517 AG
1x - Updated Turbo Return Tube - 6C3Z-9T515-A
1x - Turbo Mounting Hardware - 3C3Z-9T514-AG
2x- Block Drain Fumoto Valves - F-108N
1x - Set of ARP Head Studs - 250-4202
1x - Bottle of ARP Assembly Lube - 100-9910
1x - Set of RiffRaff Intercooler Boots - RDPABK03-06
1x - Racor Oil Filter
1x - Racor Fuel Filter Set

Head Lifting Bracket
EGR Delete


I will also be replacing the water pump and hpop while I'm in there with some lower mileage ones because I am assuming mine are original.

By the looks of it I some how ended up with some extra stand pipes and dummy plugs, oh well.

Broke quite a few things...

Some pictures cause I know you all love them.

Space that I'm working with



My Heater


Grill and Bumper Removed


Batteries out, coolant drained, I/C pipe removed


Odd colored fin on the turbine wheel. I guess it doesn't look too bad for 160k miles, assuming it's original.



For some reason I had a brain fart and couldn't figure out how to remove the headlights, so that kinda slowed me down cause I wasn't able to remove the header panel. I found some other stuff to do in the mean time though.


Broke the dang fuel filter cap! My own fault I guess.. More on this later after I messed it up even more!


Got aft and coolant all over the place. I took quite a few facefulls. Eventually I learned that if it looks like there's a chance there might be fluid in the line look away!


All the crap in my radiator, is there an easy way to clean this?


Radiator, header panel, and crossmember all out! Now onto that pesky fan and shroud.


Tried a few things including this with a pipe wrench. I eventually gave up on that for the day until I could read up on the best way to do it.


EGR Valve out ( I cleaned this less than 7k miles ago )


A Look inside the manifold



Kinked the fuel line trying to remove it. I bent it back so I think it will be okay if I don't mess with it. Notice the zip ties, they are not from me. Seems as if this engine has been torn into before..


Got the filter housing off. I told you I messed up the fuel filter and cap up more didn't it I?! Not really sure what to do with it at this point.. I tried using a screwdriver and banging it with a hammer in order to start turning the cap, ended up cracking nearly half of it off.. Oh well


Got the throttle body off


Connector tab broke when I removed it. Will I be okay without it or should I look into splicing a new one in?



And that brings me to where I ended today. Got a lot of the wiring disconnected, and the turbo bolts out. They came out pretty easy I just can't get the y'pipe clamp off! I know they get seized on there after a while and you can usually give them a tap with a flat head to free them up but this one just won't free up.


Where I ended today


That radiator fan is still in there, plan on trying to get that out tomorrow. I put in about 4 hours today. I really hate all those black clips/pins that Ford put on everything. I'll have to find a source for those because I need to replace a fair amount of them.


Anyone's comments and tips are welcomed and appreciated!

Last edited by Korx; 01-01-2013 at 05:58 PM.
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Old 01-01-2013, 05:20 PM
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Nicely done. Keep it up .
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Old 01-01-2013, 05:26 PM
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Either rent the fan clutch tool or give it a few hits with an air hammer in the direction to unscrew it.
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Old 01-01-2013, 05:27 PM
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I need to spin it counter clockwise correct?
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Old 01-01-2013, 05:31 PM
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Yea I'm pretty sure it's just plain ol right hand threads

I rented a tool from oriellys, it wasn't the "correct" tool but one of the wrenches (42mm I think) fit the nut and I put a screwdriver in the pully hole. It came right off.
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Old 01-01-2013, 05:37 PM
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I'm gonna try the screwdriver and long pipe wrench trick tomorrow and if no I'll have to head to advance or autozone to see what they have for rent.
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Old 01-01-2013, 05:37 PM
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Quit breaking stuff, lol. You should get that cap off by tapping with a screwdriver before removing it from the motor. Autozone has the socket you can pick up. Only thing, I would have cleaned up under the engine bay before digging in, but it rarely gets below 50 down here. Looks good.

Sent from my phone that somebody didn't help me get.
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Old 01-01-2013, 05:38 PM
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Oh and if your not getting head work done and don't have exhaust leeks, there's no point in taking the manifolds off the heads. You can save the money for the gaskets and the chance of breaking off a stud in the head.
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Old 01-01-2013, 05:39 PM
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Good work, keep it up.
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Old 01-01-2013, 05:39 PM
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Good job, those plastic clips get old and brittle plus the plugs get stuck together. a little wd-40 helps.
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