DTSFab.com (Desert, Trail and Sand)
Machinery, Trailers, Toyhaulers and Motorhomes => Trailers, Toyhaulers and Motorhomes => Topic started by: Enemy on May 13, 2014, 09:42:34 AM
-
A quarter mil on the odometer and its time to do some inspection and upgrades.. Very lucky to have dug into it when I did for many little things could have easily left me stranded if not addressed soon. For starters, lately been noticing boost dropping off. Ok, so the HPOP is tired, the turbo needs rebuilt, the IPR valve is cooked, and the shitty stock fuel system is having a hard time keeping up with the Stage 1 injectors. Cant get mad about it, Im the second owner and its made it this far right?
First pull the fuel bowl and really get an idea how exactly this conglomerate of shit works.
Pretty, isnt it?
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2F0427041541_zps7b073b9b.jpg&hash=b7b01c1986266dd3bbce0a99d9925709ec825994) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/0427041541_zps7b073b9b.jpg.html)
This is the water separator, fuel heater, fuel filter, fuel reservoir, and pressure regulator all in one..A two stage mechanical pump sits below it riding on a cam lobe that uses the low side to first lift the fuel from the tank for conditioning and filling the reservoir, then the high side to pressurize the rails to between 35 and 70 psi. (If you can read the gauge) Notorious for leaking diesel into the oil pan and barely keeping up with stock configurations. Mine was doing both.
My fix is an E-fuel update like the newer Superduty's with an electric pump and filtration/conditioning system on the frame rail back by the tanks. FuelLab Prodigy brushless pump feeding the rails with an Aeromotive regulator keeping the fuel pressure at a constant 65psi. Starts and idling are vastly improved!
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2F0508041737_zpsc7829433.jpg&hash=7ad7c8caec850d75873d9be094135f3947bf1e8e) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/0508041737_zpsc7829433.jpg.html)
Next, onto pulling the turbo.. What a friggin nightmare.. The pedestal has a Electronic Backpressure Valve reservoir built into it to activate a flapper in the downpipe flange. Usually activates for speeding up warmup on cold start.. and cycling while going down the road at operating temps to really piss off the driver and sound like someone shoved a bunch of bananas in the tailpipe. Some guys like to put them on a switch to work like an engine brake, I choose to delete it to lower EGTs, gain some flow, and put all the oil in that pedestal where it belongs.. In the turbo! As a bonus, what was a nightmare to pull out was simple to put back in with it out of the way!
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2F0428042145_zpsc033a4ad.jpg&hash=3e50709156b7fc2f4152565962e1705b60ab3f8e) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/0428042145_zpsc033a4ad.jpg.html)
While it was out, I also found this..
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2FIMG_1421_zps0cf7d822.jpg&hash=f4682111dac02984fd91d856e88f6fdb08750f53) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/IMG_1421_zps0cf7d822.jpg.html)
DS did some searching and it has all the signs of being over spun and about to let go of a vain, another thing the stock setup is known for doing when one starts adding hot tunes to them and going past 30psi. Whod a thunk it. Strange things happening when tip speeds break the sound barrier?? Interesting...
Good thing I have options!
66 mm compressor conversion..
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2FIMG_1425_zps1f83134e.jpg&hash=be1dfcc6c98c71b1c5726dada20c1a2c74204f33) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/IMG_1425_zps1f83134e.jpg.html)
My buddy has been getting into ceramic coating so while it was out... ;D
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2FIMG_1431_zps424f33a1.jpg&hash=4e300049ef50fdbb0248afb0e7bf62b786ee18ec) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/IMG_1431_zps424f33a1.jpg.html)
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2FIMG_1430_zpsed481948.jpg&hash=d71bed65f440a319c702c141cb314976a04ca817) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/IMG_1430_zpsed481948.jpg.html)
Upgraded the intake plenums to the newer 3" style in preparation for intercooling down the road when the truck get a restoration. No more blowing through a straw!
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2F0505042125_zpsb7cc60b5.jpg&hash=65f1ce592fd214418a85be0f8b6c12cf97a67c0a) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/0505042125_zpsb7cc60b5.jpg.html)
And the finished product! Not shown is the Adrenaline high pressure oil pump upgrade for greater volume of oil to the bigger injectors, absolutely needed if I go any further with HP in the future.
Now just gotta see if It will last to OK and back! :)
(https://dtsfab.com/proxy.php?request=http%3A%2F%2Fi516.photobucket.com%2Falbums%2Fu329%2Fbeerfarm1%2F1997%2520F250%2520Powerstroke%2F0511041433_zpsed106ad9.jpg&hash=350f0c0e922de0223b23da3cc9bafbb7f80c593b) (http://s516.photobucket.com/user/beerfarm1/media/1997%20F250%20Powerstroke/0511041433_zpsed106ad9.jpg.html)
-
I'm thinking burnouts and wheel stands after a few :swig: :swig: Those two rear pedestal bolts are a real #$%$% %^$% %^# pain. Really wish I had girl hands when pulling them. Cant wait to see the scares on your knuckles, and the mods under the hood!. Ceramic looks sweet!!!
-
I as looking at doing similar upgrades to My 97. Sold it instead and bought a lower mile 00 that had all ready been upgraded. Much easier............
-
I want to see that ceramic coat after you get to LS. If it holds up to the turbo I would consider it for the desert car headers. I have the headers on the dragster jet hot coated over 12 years ago and after 6 seasons on them still looked like new.
-
I did head studs on my 6.0 a couple years back. Worst project I have ever done and I have done several ground up builds of cars and motors. Took 10 or so total days doing it nights after work and long weekends. Had to fab a couple tools cause I refused to believe that it was "impossible" without pulling the cab off. Everything looks great!
-
I want to see that ceramic coat after you get to LS. If it holds up to the turbo I would consider it for the desert car headers. I have the headers on the dragster jet hot coated over 12 years ago and after 6 seasons on them still looked like new.
He is using Tech Line Coatings, still in the learning curve and may have to adjust process, but he's getting there. The Turbo and EBV are sprayed with cerma-chrome, good to 1400 I believe, so I'm hoping it will hold up. Nothing like being a guinea pig! He does have CBC2 as well that is for coating pistons, good to 5000*
The last set of headers I had done from a local shop lasted a year in the F150 before they turned to looking like shit.
I did head studs on my 6.0 a couple years back. Worst project I have ever done and I have done several ground up builds of cars and motors. Took 10 or so total days doing it nights after work and long weekends. Had to fab a couple tools cause I refused to believe that it was "impossible" without pulling the cab off. Everything looks great!
Thanks Punkur! I was up at a local diesel shop and they had the cab off doing head gaskets and studs on a 6.0 and said the same thing, I thought I read an article in Diesel Power where they said cab on or off, it can be done in about the same time. I need to stud this motor down the road, hope I aint pulling a cab either! Not a lot of fun..
-
I'm thinking burnouts and wheel stands after a few :swig: :swig: Those two rear pedestal bolts are a real #$%$% %^$% %^# pain. Really wish I had girl hands when pulling them. Cant wait to see the scares on your knuckles, and the mods under the hood!. Ceramic looks sweet!!!
Thanks Carl! Yea, the rear bolts kept me awake one eve wondering how the hell to get them out..Watched a couple vids where a guy said "they were simple to get to! Let me show ya in this truck with the transmission pulled!" Um, no... lol..
Scars are healing nicely ;D
-
i saw this build in person last night....damn nice job enemy!!!!!!
-
Thanks man!
Learned a whole bunch about this injection system test driving with you and the scanner watching all the data! Also talked with the manufacturer today at DieselSite. VERY good info!! Also some great detail of the system here -> http://www.dieselpowermag.com/tech/ford/1304dp_heui_how_high_pressure_oil_injection_systems_work/ (http://www.dieselpowermag.com/tech/ford/1304dp_heui_how_high_pressure_oil_injection_systems_work/)
I do have to get the chip reflashed to use the extra volume of oil the Adrenaline puts out, The current program is only calling up 2800 psi and using 35% to obtain it! Target is 3200 sooo it is down on power but I think it has some potential to run pretty strong. No worries if I go bigger injectors down the road either. Bigger compressor housing and wheel changed everything. Lower psi but moving more air, so I may not be able to get it to max out anyway till I hook up the trailer behind it?
-
Thanks man!
Learned a whole bunch about this injection system test driving with you and the scanner watching all the data! Also talked with the manufacturer today at DieselSite. VERY good info!! Also some great detail of the system here -> http://www.dieselpowermag.com/tech/ford/1304dp_heui_how_high_pressure_oil_injection_systems_work/ (http://www.dieselpowermag.com/tech/ford/1304dp_heui_how_high_pressure_oil_injection_systems_work/)
I do have to get the chip reflashed to use the extra volume of oil the Adrenaline puts out, The current program is only calling up 2800 psi and using 35% to obtain it! Target is 3200 sooo it is down on power but I think it has some potential to run pretty strong. No worries if I go bigger injectors down the road either. Bigger compressor housing and wheel changed everything. Lower psi but moving more air, so I may not be able to get it to max out anyway till I hook up the trailer behind it?
That would be my thought.
-
I have a hard time "testing" too. Found one longer hill that I got run up. But you'd hit 70 quick and "testing" is not a valid excuse to :police: :police:. But hearing that boost swirl out window is fun!! Be easy on that torque convertor. nono
-
Be easy on that torque convertor. nono
Mine did not like towing the 12K gooseneck. Trans would go into default mode on long hills even with an extra large cooler. New truck has a 6 speed in it. No more trans worries.......
-
Mine did not like towing the 12K gooseneck. Trans would go into default mode on long hills even with an extra large cooler. New truck has a 6 speed in it. No more trans worries.......
i know what your saying there!!!!!!!! my 95 psd was the first automatic trans truck i have ever owned. i wanted my hand shaker back. i have a 99 psd with a 6 speed myself and a good 475 hp clutch with solid flywheel to go with it.
-
eff the clutch pedal. Allison all the way!
-
eff the clutch pedal. Allison all the way!
on the open road it's clutch for me, in town they suck! but i bought the truck just to pull the toyhauler so i'm good there lol
-
eff the clutch pedal. Allison all the way!
LAst trip through the mountians pulling about 13K trailer I got 10.5MPG, and I was not holding anybody up. The auto's can't touch that on milage. It will be interesting to see what I get on the drive back to Kansas, with everything in the trailer it's going to be about 20K............ Can't wait to go up the 550 in Colorado with that...............
-
I couldn't care less about milage. I can sit back and enjoy the drive with the Allison. I pull trailers all week long. I'll never again have a clutch (except on the toter,didn't have a choice). Hell, even new buggy is a torque converter driven Fortin sequential. If there was a way I'd convert the busa to an auto box also.
-
Where you moving to in Kansas,bdkw?
-
I couldn't care less about milage. I can sit back and enjoy the drive with the Allison. I pull trailers all week long. I'll never again have a clutch (except on the toter,didn't have a choice). Hell, even new buggy is a torque converter driven Fortin sequential. If there was a way I'd convert the busa to an auto box also.
I do! Fuel prices suck!! When I blow up the E4OD in this truck, and if I can find a ZF manual, I'm really wanting to convert it.. Id rather do the shifting, but I aint doing it all day long either! So I get your point :)
-
The cost of all these changes would go a very long way towards just buying a capable vehicle to start with ..........................................besides that I get approx 9 miles a gallon towing,13+ city,empty AND a warranty!!!!. I would have to drive for a very long time to recoup the cost of the upgrades and the time you guys put yourselves through to gain a couple mpg. Not worth it to me.
-
The cost of all these changes would go a very long way towards just buying a capable vehicle to start with ??? ???..........................................besides that I get approx 9 miles a gallon towing,13+ city,empty AND a warranty!!!!. I would have to drive for a very long time to recoup the cost of the upgrades and the time you guys put yourselves through to gain a couple mpg. Not worth it to me.
Very capable the first day I drove it..Cant afford the prices wanted for trucks today to do what this one does just as good that is paid for and keeps going up in value. Besides that, I paid $6000 for it and the upgrade cost doesn't even come close to what I could get out of it today. I'll keep driving junk, beside I like the OBS Fords ;)
-
If it was capable ,there would be no need for changes. Just my .02. I've done it both ways. With age comes lazy tho........................... ;D ;D To each their own. I have way too many things to do to spend time upgrading anything. drowning
-
well mpg's do matter to myself as well but not as much as a comfortable trip towing my load and the peace of mind of the reliablility and longevity of my engine and driveline as well being able to maintain speeds. my 1999 f350 diesel dually 4x4 quad cab may be extreme over kill for what I am pulling but it does the job more than enough on every aspect accept mpg's imo. now I say this because the best mpg's I have seen pulling 10k to 11k have been 9.3 mpg and worst at 7.5 mpg in a 50 mph cross wind for 6 hrs of that drive. of course I probably should say that 9.3 mpg is at 75 mph with the cruise set on a pretty warm day. with my 1995 f250 2wd ext cab obs I got 9.5 almost all the time except in extreme wind, pulling the same load ( my toy hauler) down the same roads at the same speeds. that truck weighed in at 6850 lbs on the scale. where I haven't weighed this 99 dually, all the posts I have read of others weighing there's, looks to put it at 8500 lbs to 8900 lbs. so a little bit more weight than the 1995 and it had 4.1's. this 99 has 3.73's, I wish the 99 would have 4.1's but it is what it is. I always got 19 mpg at 75 to 80 mph in the 1995 empty, with the air on. this 1999 only get 18 mpg at it's best empty at those same speeds on the same roads, so not the worst considering the extra weight, tires and wind drag compared to the 1995 obs truck. I will say that I do prefer the shape of the hood and dash in the obs truck over super duty ( sd ) body style for vision and practical use! now I keep getting told that If I would slow down while pulling I would get better mpg's.........prob right ......but i'm not slowing down!! rofl I built the suspension on the camper and added the fifth wheel air hitch in the bed of the truck so I don't have to rofl those mod's won't pay for themselves in mpg's but do in safety an comfort imo so that is all I needed to justify that!! rofl rofl
enemy is trying to achieve the best of both worlds with the upgrades and mod's on his truck. he has 3.55 gears so really not pulling gears but it does the job just fine, just push's the egt's to the top end of the acceptable range. empty his truck does amazing on mpg's! so with these mod's he not only brings the power up and gauge #'s down to add to the longevity of the engine but does slightly increase mpg's. enemy as well as myself are not willing to allow or pay, just any diesel mechanic, to work on our trucks simply due to lack of pride in soooooo many of the industry today. in doing these mod's we also gain the knowledge of future repairs and diagnostics. there is one diesel mechanical shop I do trust called c&c complete in bennington neb. all of these guys race there trucks, have blown many parts up , have tried many of the aftermarket performance parts and know the powerstroke diesel's inside and out. the one down side to them is all there thoughts are on extreme racing so they don't always pick the daily driver friendly parts rofl the best shop imo though!! enemy is correct our trucks are paid for so a few mod's are nothing more than making sure the truck does exactly what we want them to do in a very comfortable way just like our sand rails rofl rofl since I no longer use a truck on a daily basis anymore, I personally can't afford or justify a $60k truck just to sit on standby for pulling my toyhauler camper, it would be nice but just can't. now I know it does take a lot of time that most don't always have and I can't speak for enemy but for myself, I actually find it fun to do the mods or repairs on my trucks. ;D
-
I couldn't care less about milage. I can sit back and enjoy the drive with the Allison. I pull trailers all week long. I'll never again have a clutch (except on the toter,didn't have a choice). Hell, even new buggy is a torque converter driven Fortin sequential. If there was a way I'd convert the busa to an auto box also.
these are damn nice....a bit pricy but damn nice. you will really like that. in a truck the auto is nicer in town or city driving! but I grew up with a stick and pre-fer them to this day for pulling but no fun at all in town especially driving a dually in the city!! the lanes are not wide enough rofl rofl
-
well mpg's do matter to myself as well but not as much as a comfortable trip towing my load and the peace of mind of the reliablility and longevity of my engine and driveline as well being able to maintain speeds. my 1999 f350 diesel dually 4x4 quad cab may be extreme over kill for what I am pulling but it does the job more than enough on every aspect accept mpg's imo. now I say this because the best mpg's I have seen pulling 10k to 11k have been 9.3 mpg and worst at 7.5 mpg in a 50 mph cross wind for 6 hrs of that drive. of course I probably should say that 9.3 mpg is at 75 mph with the cruise set on a pretty warm day. with my 1995 f250 2wd ext cab obs I got 9.5 almost all the time except in extreme wind, pulling the same load ( my toy hauler) down the same roads at the same speeds. that truck weighed in at 6850 lbs on the scale. where I haven't weighed this 99 dually, all the posts I have read of others weighing there's, looks to put it at 8500 lbs to 8900 lbs. so a little bit more weight than the 1995 and it had 4.1's. this 99 has 3.73's, I wish the 99 would have 4.1's but it is what it is. I always got 19 mpg at 75 to 80 mph in the 1995 empty, with the air on. this 1999 only get 18 mpg at it's best empty at those same speeds on the same roads, so not the worst considering the extra weight, tires and wind drag compared to the 1995 obs truck. I will say that I do prefer the shape of the hood and dash in the obs truck over super duty ( sd ) body style for vision and practical use! now I keep getting told that If I would slow down while pulling I would get better mpg's.........prob right ......but i'm not slowing down!! rofl I built the suspension on the camper and added the fifth wheel air hitch in the bed of the truck so I don't have to rofl those mod's won't pay for themselves in mpg's but do in safety an comfort imo so that is all I needed to justify that!! rofl rofl
enemy is trying to achieve the best of both worlds with the upgrades and mod's on his truck. he has 3.55 gears so really not pulling gears but it does the job just fine, just push's the egt's to the top end of the acceptable range. empty his truck does amazing on mpg's! so with these mod's he not only brings the power up and gauge #'s down to add to the longevity of the engine but does slightly increase mpg's. enemy as well as myself are not willing to allow or pay, just any diesel mechanic, to work on our trucks simply due to lack of pride in soooooo many of the industry today. in doing these mod's we also gain the knowledge of future repairs and diagnostics. there is one diesel mechanical shop I do trust called c&c complete in bennington neb. all of these guys race there trucks, have blown many parts up , have tried many of the aftermarket performance parts and know the powerstroke diesel's inside and out. the one down side to them is all there thoughts are on extreme racing so they don't always pick the daily driver friendly parts rofl the best shop imo though!! enemy is correct our trucks are paid for so a few mod's are nothing more than making sure the truck does exactly what we want them to do in a very comfortable way just like our sand rails rofl rofl since I no longer use a truck on a daily basis anymore, I personally can't afford or justify a $60k truck just to sit on standby for pulling my toyhauler camper, it would be nice but just can't. now I know it does take a lot of time that most don't always have and I can't speak for enemy but for myself, I actually find it fun to do the mods or repairs on my trucks. ;D
No argument here. You guys just have too much time on your hands is all and I'm jealous. ;D ;D I've just never been one to mod(much) my street driven anything.They get me tickets just fine as they are......................
-
these are damn nice....a bit pricy but damn nice. you will really like that. in a truck the auto is nicer in town or city driving! but I grew up with a stick and pre-fer them to this day for pulling but no fun at all in town especially driving a dually in the city!! the lanes are not wide enough rofl rofl
I grew up with that effin stick also. roads are plenty wide even here in Poverty, Kansas ;D People say my buggy can't follow SxS's through the LS quad trails...................LMAO LMAO LMAO LMAO LMAO LMAO LMAO LMAO Same with city streets. rofl rofl rofl rofl rofl
-
lol well if you swerve at them here they make room rofl
-
Swerve hell,I run right over the "competition". hehheheee
-
Swerve hell,I run right over the "competition". hehheheee
i can't get away with that in this anal retentive state rofl
on another note.....the dual fuel filter set up enemy has installed is definitely needed around these parts. i knew our diesel fuel was dirty but had no idea just how dirty until i looked at the clear water separator lower section of his filter. the crap built up in the bottom is nasty and he did replace his tanks so it's not rust! i have purchased on for my truck but won't have the time to install it before the trip!
-
It's not the fuel,it's the storage tanks. Same deal with gasoline.
-
It's not the fuel,it's the storage tanks. Same deal with gasoline.
either way that is not good for injectors, pumps etc etc
-
No ,but that is the purpose of the factory filters..................................changed regularly. I'm much more concerned with water in the fuel so often that OEM's have to put water sensors and drains on filters. That is just BS with all the regs there are on fuel storage in this country. Ever wonder why the big push to alky blended gas? At least one factor has to be the ability to absorb water and move it through the supply pipeline instead of being just water at the bottom of your gas tank,stranding you on the side of the road. Remember the days of adding HEET(alcohol mostly) to your gas in winter?
-
yes i do remember and they still sell it lol. the secondary filter enemy and i bought has a clear bulb under it to catch the water with a drain valve so we can drain the water. how much get mixed and sent through ......hard to say and that is bad which is the reason we pour additives in our fuel to help with that and lube inj's. you are right that is the reason for the fuel filter but after seeing the crap in the bottom of his new system and what was sitting in the bottom of his factory filter housing, i will add this to mine. inj's aren't cheap on these trucks so $100 and a little time is just added cheap ins imo. i add rev x to my oil and fuel tank. https://www.revxoil.com/REV-X_Applications_Pickup_Truck.aspx
-
I understand but I also have also never had a fuel related issue that was not purely a local storage issue with water in the ground tanks. I guess I'm just not that concerned .