2002 F250 diesel - discovery and build thread.

[Snoranger]

its a c130 with gear that parachutes out of it.....

 

[scotts90ranger]

Vacuum system for drawing in the new coolant under vacuum to reduce or prevent air bubbles. I had to look it up. I went ahead and ordered one.

Anyway, it uses a pressurized air source from your compressor to create a vacuum in the system. Then you shut off the vacuum source and open the valve for the hose coming from the jug of new coolant. The vacuum sucks in the coolant. Repeat until system is full. (If I understood the directions properly) Similar to vacuum brake bleeder.

Late to the party but I was going to suggest that, I have the harbor freight vacuum fill kit, works just fine and was only like $50... put coolant in 5 gallon bucket and just let it suck out of that or the hose usually fits in the coolant bottles, that's what I did with the Explorer a few weeks ago...

 

[Curious Hound]

Well, I did it today. I got everything flushed pretty good. The system seemed pretty clean. I reversed the heater core hoses. That required removing one of the intercooler pipes. So that got a good cleaning while it was out. I don't think I got all the tap water drained out, because I only got 5.5 gallons back in the system. Total volume is around 8 gallons. I should have looked for a drain plug on the block. Anyway. It should be good. Filled with Rotella ELT coolant. New upper and lower radiator hoses. I like the way the new upper hose is routed around the serpentine belt instead of through the middle. I didn't get the belt changed. I ordered the wrong one. It's about 3/4" shorter than the one I need. Broke the hose nipple off the MAP sensor and had to replace that. Boy, are those things pricey. Found a soft coupler blown out on the hot intercooler pipe near the turbo. I just happened to have a 3" reinforced silicone coupler left over from the Ranger snorkel project. So that's fixed. Also found some little hose behind the fuel filter bowl that wasn't connected. It was attached to a 1/4" hard tube that goes somewhere under the fuel filter bowl/ HPOP area. Fixed that with a new piece of fuel hose. Also lubed the ball joints and tie rod ends while it was up on the ramps. What a day.

New upper radiator hose routing. There is even a curved place on the alternator bracket that the hose fits into and can be strapped in place.

Blowout on the intercooler piping.

Hard to see. But right in the center (below the white label on the wire loom) is the disconnected hose behind the fuel filter bowl. Bowl in upper left, intercooler pipe on the right, glow plug relay upper center,

 

[Curious Hound]

Today, I finished installing a remote starter switch to ne used for troubleshooting or starting with ether when there are problems. While I was there, I noticed wetness around the top and sides of the water pump. I'll need to take a look at that with the engine hot and running. But it looks like I should prepare to replace that soon. That might also be the chirp I hear, particularly when the engine is cold.

Protected Remote start switch at core support, driver side.

 

[Curious Hound]

Today, I removed the complete fuel filter bowl, disassembled, cleaned and rebuilt it with new seals. Not a bad job to do. But it has its challenges. I believe this will get rid of some fuel leaks, since part of the kit included rubber seals for all the fuel line connections. There is a check valve assembly inside. So, maybe new o-rings in that may help my cold start issue slightly. I also got to see the high pressure oil pump. It has a Jasper label on it. So that has been replaced at least once. I also found the fuel heater/water in fuel sensor electrical connector unplugged. And, now I know that the little hose I found disconnected a few weeks ago, is just for the drain valve. I found the other end of that and attached a hose to it so I could drain it into a bucket.

It's filthy in there.

The parts bag came with a cool sheet to match each seal with a life-size picture and description of where it belongs

Left is the heater/water in fuel sensor connector. Tight us the manual drain valve assembly.

Rebuilt HPOP

All back together and refilled.

 

[Curious Hound]

New water pump and fan clutch yesterday. The squeak and chirp are gone, hopefully, the leaks are gone too. Also got the right serpentine belt and replaced it. Old belt goes behind the seat as a spare. Did some more cleaning around that part of the engine bay. Job would have gone much quicker if I didn't have so much gunk to clean up. I'm sure I ordered a heavy duty fan clutch. But it's not as big as the old one. Hope I didn't mess that up.

New pump in.

 

[Curious Hound]

Also harvested a new steering column from the junk yard, Friday. This one has all the cruise buttons, the airbag cover isn't torn and held on by electrical tape and the cover on the OD off button is intact. I'll clean and lubricate it and replace the plastic bushings on the shifter tube. Then it'll be ready for installation. I already cleaned a good bit if mildew and grime off the steering wheel.

 

[Curious Hound]

It's a Powerstroke Christmas Day. Parts arrived - new injectors, new glow plugs, wiring harnesses for under the valve covers, valve cover gaskets, new air filter housing and intake plenum and a tuner. There's gonna be a major transformation next week. It's a shame I have to work this weekend.

Special.thanks to @Mattman347 at Irate Diesel.com

 

[Curious Hound]

Drive shaft carrier bearing is finished. Of course, I had ordered the wrong one. The shaft stepped up to a larger diameter where the bearing sits. It was a bear to get off, even with a bearing splitter and strong back puller. But only a 4 hr job including going to Advance for the correct bearing.

It did turn out to be a headache job. During re-assembly, I had one end if the shaft resting on a small jack stand while I slid the splines together. The stand fell over and its top put a small gash in the top of my head. I almost always wear a baseball cap. But had neglected to put it back on when I got home from the parts store (motorcycle trip). There was a contractor about 35 ft away filling his water totes from the hydrant. He yelled "Are you ok?" I said yeah. I think so. Then he said "you're bleeding.". I started thinking "wow. He can see that from 35 feet away?". Then I felt it running down my scalp. I hope it scabs over good before I go to bed tonight.

Yay!

 

[scotts90ranger]

Yeah, those are fun... I changed the one on my F350, the stupid aluminum strap thing holding the assembly together was covering the arrow pointing forward on mine so it ended up backward apparently, it's still that way, doesn't seem to care...

I've heard the injectors aren't too bad to do other than all the oil that gets in the cylinders when you pull them out... I haven't seen if I have enough room to pull the plugs out of the back of the heads to drain the oil that goes there before I do it eventually...

 

[bilbo]

I'll second that. I did the one on my F250 and it isn't something I'd stand in line to do again. Sorry to hear about your noggin, hope that heals up fast.

Mine had rubber bellows covering the blue part of the drive shaft and I see yours does not. I figured it was to keep dirt out of the sliding splines. Is yours missing or did some trucks not have that?

 

[Curious Hound]

I'll second that. I did the one on my F250 and it isn't something I'd stand in line to do again. Sorry to hear about your noggin, hope that heals up fast.

Mine had rubber bellows covering the blue part of the drive shaft and I see yours does not. I figured it was to keep dirt out of the sliding splines. Is yours missing or did some trucks not have that?

The boot is probably.just missing. I cleaned and lubed the splines. Not too worried about the boot right now.

 

[Curious Hound]

Yeah, those are fun... I changed the one on my F350, the stupid aluminum strap thing holding the assembly together was covering the arrow pointing forward on mine so it ended up backward apparently, it's still that way, doesn't seem to care...

I've heard the injectors aren't too bad to do other than all the oil that gets in the cylinders when you pull them out... I haven't seen if I have enough room to pull the plugs out of the back of the heads to drain the oil that goes there before I do it eventually...

One procedure I've read says to leave the glow plugs out, put the valve covers on temporarily and crank the engine to push the oil out of the cylinders. Sounds like a reasonable way to handle that

Edit: Read it again. It also mentions sticking a small tube down in the cylinders and sucking the oil out first. I need a gullible helper.

 

[Curious Hound]

I started tearing apart my powerstroke for what I expected to be about 12 hrs of repair work. But inadvertently stripped the threads out of a hole in the Y casting where the exhaust up-pipes meet the tutbo inlet. Another $100 of parts on order. Will probably have to remove the turbo to replace that casting. All this to fix some exhaust leaks. But the MAIN job I'm trying to accomplish is injector and glow plugs replacement. Also found out that I need a new wheel in the turbo. That's going to have to wait.



Pulled the threads out of the casting (upper part) where this flange clamps on. This is one of the joints that has been leaking.

Impeller should not look like that. This engine has eaten dirt.

Driver side valve cover exposed. After some cleaning, I'll be ready to pull that off and do the injector and glow plug replacement.

Found a penny by the passenger side valve cover. Heads up. But I don't feel like I had very good luck today.

 

[Curious Hound]

Oh, yeah. Need to do something to repair these wires for the map sensor.