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Discussion Starter #1 (Edited)
Sunday afternoon I started the tear down for ARP studs, OEM gaskets, blue spring upgrade, standpipes and dummy plugs, 6.4 banjo bolts, upgraded STC fitting, upgraded IPR screen, upgraded oil feed and drain tubes and bulletproof oil cooler.:woot:

So far I've run into two minor setbacks both of which the ORG has come to my rescue within minutes. I,m 11 hours in and have the hood, grill, fan shroud, alternator, manifold, EGR cooler, turbo and oil cooler out. I need to get the tool to remove the fittings at the bottom of the rad for the transmission cooler lines. If I don't get one by tomorrow I will just cut them and use compression fittings to put them back together. I want to remove the rad and intercooler leaving the condensor in place to install the Bulletproof cooler. This way I won't have to evac the AC. The hood I removed so I can use my gantry crane to lift off the heads as space is limited and a hassle to use my engine hoist to lift them off. Lucky for me I have a furnace in the garage as it's pretty flippin cold out the last couple of days. -2F Sunday.:please: Supposed to be up around 45F by Wednesday.:thumb:

As soon as I get a few minutes I will post some pictures, (They start on post #14 of this thread) just trying to get to the heads so I can get them to the machine shop ASAP.
 

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I just finished up with the same project and on my transmission lines I just unhooked the nuts that screw into the radiator. I was a little aprehensive about doing it at first but, it's no problem you can get the nuts hooked back up without a problem. The tank will move around inside the radiator but, you can get it lined back up without issue.
 

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I just finished up with the same project and on my transmission lines I just unhooked the nuts that screw into the radiator. I was a little aprehensive about doing it at first but, it's no problem you can get the nuts hooked back up without a problem. The tank will move around inside the radiator but, you can get it lined back up without issue.
Thanks. Sounds good if I don't get the tool in the morning I will try that before cutting them.:thumb:
 

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are you doing this with the cab on? i have an early 04 I am about to do the same project but I was wondering if studs can be done with the cab on? Especially the drivers side head with that lower rear stud....is there enough clearance to lower that sucker on there?
 

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Discussion Starter #5 (Edited)
are you doing this with the cab on? i have an early 04 I am about to do the same project but I was wondering if studs can be done with the cab on? Especially the drivers side head with that lower rear stud....is there enough clearance to lower that sucker on there?
Yes I am. And yes the back lower drivers side back can be done. You have to loosen the rear bolt and pull it up to clear the threads and use a rubber band or tie to hold it in place because there isn't enough room to pull it out. lift out the head and Instal is the same with stud held in place in the same manner. I will post pics
 

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Perfect thank you. Also, did u do a coolant system flush before or after you did this? I have read a lot about doing the egr and oil coolers and people that have done oil coolers have clogged up again within a couple hundred miles. I plan on adding an aftermarket coolant filter but I want to avoid this happening to me.
 

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Perfect thank you. Also, did u do a coolant system flush before or after you did this? I have read a lot about doing the egr and oil coolers and people that have done oil coolers have clogged up again within a couple hundred miles. I plan on adding an aftermarket coolant filter but I want to avoid this happening to me.
Did my coolant flush about 9K back and installed my coolant filter then. Even after the thorough flushing the first filter plugged after just 500 miles and again at 2K with casting sand. The third is still not plugged after about 5.5K but I'm going to change it anyways after all this work. Do your flush ASAP and then put on your coolant filter at the same time. Just remember all the crap will be loosened up and sent through your oil coolar and EGR cooler. You will probably see your delta, spike after the flushing as mine did it got up to 14degrees. I wasn't overly worried as I had already done the EGR delete.
 

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Ya but unfortunately I cant drive my truck as is....so I cant do the coolant filter and run it. Its billowing white smoke and building pressure right now. So since I cant do a flush before all this work I am about to do, is there a procedure to flush it out before I ruin a new oil cooler? I am going with the bulletproof egr cooler but the $$$ isnt there for the oil cooler setup.
 

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-2*F? That's absolutely CRAZY... :D We were in the low 80's yesterday... :poke

Best of luck, man. I would be very interested to see your pics.
 

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-2*F? That's absolutely CRAZY... :D We were in the low 80's yesterday... :poke

Best of luck, man. I would be very interested to see your pics.
A little better today about 28degrees and tomorrow is supposed to be about 50. That's t-shirt weather for us up here. Won't have to have the heat on in the garage and will have the door open :woot::woot::woot: Will be pulling the heads tomorrow:nod::nod::nod: Just taking a break and back out to pull the standpipes, dummy plugs, injectors and maybe even loosen the head bolts.
 

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A little better today about 28degrees and tomorrow is supposed to be about 50. That's t-shirt weather for us up here. Won't have to have the heat on in the garage and will have the door open :woot::woot::woot: Will be pulling the heads tomorrow:nod::nod::nod: Just taking a break and back out to pull the standpipes, dummy plugs, injectors and maybe even loosen the head bolts.
SWEET! At 28*, shouldn't the camera be thawed enough to start working... :hehe: Good luck pulling those heads. I wouldn't want to do that in ANY weather. :D
 

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SWEET! At 28*, shouldn't the camera be thawed enough to start working... :hehe: Good luck pulling those heads. I wouldn't want to do that in ANY weather. :D
Camera has been working just haven't stopped long enough to upload to Photobucket. Just want to get the heads to the machineshop then I'll slow up and post pics.:thumb:
 

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are you doing this with the cab on? i have an early 04 I am about to do the same project but I was wondering if studs can be done with the cab on? Especially the drivers side head with that lower rear stud....is there enough clearance to lower that sucker on there?
Everybody talks about the bottom rear drivers side bolt. It was a flipping breeze compared to the passenger side with the AC and heater box in the way. Think I'll be removing it for the install. :crazy::crazy::crazy:
Got both heads off today. I'll take some time to download and arrange pictures so I can post in a day or two. Cheers, :beer:
 

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Discussion Starter #14
Day 1, Removed hood, grill, batteries, upper fan shroud, drained coolant, removed air filter assembly, Wiped down and or washed all parts as removed to hopefully save time in the end.



Hood removed and pulled into my garage. Yes all you lucky Texans, Arizonans etc, that is snow on the cowl. Uhfortunately not enough headroom to lift cab but the gas furnace is a bonus for keeping warm at -2 deg F.



Grill removed for protection as I didn't want to crack it leaning over it. Zoodad cutout modification for air intake.



Clear view straight into supergreen filter through Zoodad mod



Door upholstery tool was excellent for removing push pins and prying up parts like the EGR valve etc.



New parts washer on it's virgin run cleaning intercooler boot clamps.



Hood safely stored out of the way on back of truck.



Oil in intercooler tube from CCV. Soon to be history. Will be deleted as rebuild progresses
 

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Day 1 continued,:icon_ford:



More oilly residue from CCV. If not removed will breakdown the rubber of the CAC hoses.:mad:



Steps over wheels work absolutely awesome, real back savers. $24.95 each half price at Pincess Auto one on each front wheel. Fold up when not in use for easy passage, highly recomended!!!!!!:thumb::thumb::thumb:



Step folded up out of knee skinning contact LOL:eek:hnoes::eek:hnoes:



Working space is limited but adequate. Atleast it's warm:woot:
 

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Pics look great! It is a little cramped, but I can't imagine doing this kind of job out in the cold... Love the snow on the cowl! :D
 

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Pics look great! It is a little cramped, but I can't imagine doing this kind of job out in the cold... Love the snow on the cowl! :D
Yeah, not quite as warm as Arizona LOL. we had a light dusting the night:hehe: before I brought it into the garage to start the bulletproofing. Warm inside though. Past few days have been t-shirt weather about 48 degrees and sunny today and yesterday. Probably 85 or more down there:look: Spent the best part of today with some barstock removing the old gaskets from the heads. Forgot what it was like, arms and shoulders are killing me. It'll be into the hottub tonight:thumb::thumb::thumb:
 
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