• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' and react to posts.

2002 F250 diesel - discovery and build thread.


ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
Ahhhh. There it is. Now, I'm doing a little cleaning.
20231114_134033.jpg


20231114_141902.jpg


Dirt pile is building up underneath. I'll use the blow gun and putty knife for most of it, then spray with degreaser and rinse with the hose. I should use the pressure washer. But this projectbis already going way overtime. All intake and oil openings are covered to keep Dirt out.
20231114_141953.jpg
 


scotts90ranger

Well-Known Member
RBV's on Boost
Joined
Feb 28, 2001
Messages
7,817
Reaction score
4,063
Points
113
Location
Dayton Oregon
Vehicle Year
1990, 1997
Make / Model
Ford
Engine Type
2.3 (4 Cylinder)
Engine Size
2.3 Turbo
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6
Tire Size
35"
If it's any consolation they're just as fun to put back in... :)

Turbo's definitely different, on the older ones they bolt on from the bottom not the top... I had to take the pedestal off to get the turbo out.
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
If it's any consolation they're just as fun to put back in... :)

Turbo's definitely different, on the older ones they bolt on from the bottom not the top... I had to take the pedestal off to get the turbo out.
Yeah. That was great fun. Just 2 bolts holding it on. Felt like I was going to break them. Really, the up-pipe is worse than the turbo. I'm going to look at my credit card balance tonight and seriously consider the new Impeller and rebuild kit before I put it back in. Knowing how it goes together, I guess it might have been possible to get that Y casting out without remivungbthe turbo. But, even the flange clamps on the hot piping have been fighting me.
 

racsan

Well-Known Member
Supporting Member
TRS 20th Anniversary
TRS Event Participant
Joined
Aug 17, 2007
Messages
4,882
Reaction score
4,261
Points
113
Location
central ohio
Vehicle Year
2009
Make / Model
ford/escape
Engine Type
2.5 (4 Cylinder)
Engine Size
2.5/151 I-4
Transmission
Automatic
2WD / 4WD
2WD
Tire Size
235/70/16
My credo
the grey-t escape
Sounds quite pricey. We had a tractor with a turbo , ‘76 1855 oliver. every 2 or 3 years the turbo would need replaced, wouldnt work without it. New ones were no longer available for it so had to keep getting rebuilt units. Dad only ever had one diesel truck, a 86 F250 2wd with the 6.9 (420) international na. Had nothing but problems with it. He about swore off ford completely.
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
Sounds quite pricey. We had a tractor with a turbo , ‘76 1855 oliver. every 2 or 3 years the turbo would need replaced, wouldnt work without it. New ones were no longer available for it so had to keep getting rebuilt units. Dad only ever had one diesel truck, a 86 F250 2wd with the 6.9 (420) international na. Had nothing but problems with it. He about swore off ford completely.
Seems like everything is pricey these days. I'm putting a good bit of time and money into this truck right now. But, at 274,000 miles, you expect it to need some love. I'm still confident that I'm about to have a great engine in a mediocre body. If I had to pay for labor on all this, there's no way I could afford it. The 1990 7.3l idi that I had years ago was a great truck. This one should be even better... soon. Real soon
 

bobbywalter

TRS Technical Staff
TRS Event Staff
V8 Engine Swap
TRS Technical Advisor
TRS Banner 2012-2015
TRS 20th Anniversary
Ugly Truck of Month
TRS Event Participant
Joined
Aug 9, 2007
Messages
23,470
Reaction score
4,661
Points
113
Location
woodhaven mi
Vehicle Year
1988
Make / Model
FORD mostly
Engine Type
V8
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
KIMG0391.JPG
KIMG0390.JPG


Run that number......




It's dusted a bit but feels ok...

KIMG0389.JPG



Might still be there...
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
View attachment 101737View attachment 101739

Run that number......




It's dusted a bit but feels ok...

View attachment 101740


Might still be there...
The 383 is the same. Mine has different letters after it. Half of the number on my label is rubbed off. Probably same family but that truck just looks earlier. Let me see what kind of price Matt comes up with for parts. Even putting a used turbo in, I would rather freshen it up with a rebuild to prevent having to pull it again any time soon. There's one in the yard about 5 miles from my house. But it's lightly dusted and has a bunch of play in the bearings. Mine feels solid. No end play. Maybe a couple thousandths of radial play. I can barely feel it.
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
I'm back at it today. Driver side injectors and glow plugs out.
20231117_101900.jpg


20231117_105157.jpg


Yuck.
20231117_105115.jpg


20231117_111528.jpg


For anyone doing this job, note that on some models, injector number 8 (I believe) is different somehow. Note the black electrical connector. The part number is different. Make sure the proper injector goes back in that hole.
20231117_111814.jpg


Valve cover gasket with wiring harness for injectors and glow plugs.
20231117_112227.jpg


The injectors are operated with high pressure oil. So, removing them dumps oil in the cylinders. Vacuum brake bleeder for the win. Later, I'll put the batteries in and turn the engine over with the glow plugs still out and valve covers back on, just to make sure the cylinders are empty. But they should be good right now.
20231117_114145.jpg
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
Well, I got injectors installed and torqued on both sides. Still have to install oil deflectors on the passenger side. Then, It's going to sit for a few days until more parts arrive. I stopped early enough to get the old injector cores shipped back and take some O-rings to the post office for AngryPossum.

I have to rebuild a battery cable. Will hopefully crimp new ends on all of them. My new up-pipes and Y-casting arrived today. But I won't mess with that until I get the turbo rebuilt. That way I can play with that mess all in one day. The new pigtail for the MAP sensor arrived today. Might install that tomorrow afternoon when I get home from helping a friend get their outbuilding subpanel tied into the main breaker panel.


Worn out battery cable connection.
20231117_122842.jpg
 

racsan

Well-Known Member
Supporting Member
TRS 20th Anniversary
TRS Event Participant
Joined
Aug 17, 2007
Messages
4,882
Reaction score
4,261
Points
113
Location
central ohio
Vehicle Year
2009
Make / Model
ford/escape
Engine Type
2.5 (4 Cylinder)
Engine Size
2.5/151 I-4
Transmission
Automatic
2WD / 4WD
2WD
Tire Size
235/70/16
My credo
the grey-t escape
This project got me to thinking: just how do you check compression on a diesel?, most likely either glow plug or injector port, but youd most likely need a much bigger guage too with the higher compression ratio a diesel has. Definitely wouldn’t be as quick & easy as a gas engine.
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
This project got me to thinking: just how do you check compression on a diesel?, most likely either glow plug or injector port, but youd most likely need a much bigger guage too with the higher compression ratio a diesel has. Definitely wouldn’t be as quick & easy as a gas engine.
I hadn't thought that far into it. As bad as the turbo Impeller is, there is certainly a possibility of other issues. It would take a very special thingy to use the injector holes fir that. The glow plug holes make the most sense to me.

I was happy to see the top of the heads nice and clean and not sludged up. My Ranger, when I got it was sludged so bad, I lost oil pressure on a steep hill because the oil couldn't return to the sump fast enough.
 

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.

bobbywalter

TRS Technical Staff
TRS Event Staff
V8 Engine Swap
TRS Technical Advisor
TRS Banner 2012-2015
TRS 20th Anniversary
Ugly Truck of Month
TRS Event Participant
Joined
Aug 9, 2007
Messages
23,470
Reaction score
4,661
Points
113
Location
woodhaven mi
Vehicle Year
1988
Make / Model
FORD mostly
Engine Type
V8
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
This project got me to thinking: just how do you check compression on a diesel?, most likely either glow plug or injector port, but youd most likely need a much bigger guage too with the higher compression ratio a diesel has. Definitely wouldn’t be as quick & easy as a gas engine.




Pretty simple on my rig.


I can change all 8 glowplugs and injectors for about 320 bux and an hour...and I don't even have to open my hood . Dirt cheap for diesel. So...needless to say Compression test is easy.
 

bobbywalter

TRS Technical Staff
TRS Event Staff
V8 Engine Swap
TRS Technical Advisor
TRS Banner 2012-2015
TRS 20th Anniversary
Ugly Truck of Month
TRS Event Participant
Joined
Aug 9, 2007
Messages
23,470
Reaction score
4,661
Points
113
Location
woodhaven mi
Vehicle Year
1988
Make / Model
FORD mostly
Engine Type
V8
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"

ericbphoto

Overlander in development
TRS Event Staff
TRS Forum Moderator
Supporting Member
U.S. Military - Veteran
TRS 20th Anniversary
VAGABOND
TRS Event Participant
GMRS Radio License
Joined
Feb 7, 2016
Messages
14,987
Reaction score
15,978
Points
113
Age
59
Location
Wellford, SC
Vehicle Year
1993
Make / Model
Ford Ranger
Engine Type
3.0 V6
Engine Size
3.0L
Transmission
Manual
2WD / 4WD
4WD
Total Lift
6"
Tire Size
35"
My credo
In theory, theory and practice are the same. In practice, they are different.
Made some progress yesterday and today. Turbo is cleaned and rebuilt. And all battery cables have new ends on them (at the battery terminal end). Would be good to replace the cables completely. But that can wait a while. I think I found 3 or 4 different cable sizes. I need to write all that down for future reference.


Old wheel vs new wheel
20231128_130454.jpg


Wow. Close tolerances.
20231128_131059.jpg


20231128_170303.jpg


20231128_170313.jpg


20231128_170318.jpg
 

Sponsored Ad


Sponsored Ad

Staff online

Member & Vendor Upgrades

For a small yearly donation, you can support this forum and receive a 'Supporting Member' banner, or become a 'Supporting Vendor' and promote your products here. Click the banner to find out how.

Latest posts

Truck of The Month


Yotaismygame
February Truck of The Month

Recently Featured

Want to see your truck here? Share your photos and details in the forum.

Follow TRS On Instagram

TRS Events

Check Out The TRS Store


Sponsored Ad


Sponsored Ad

Sponsored Ad


Amazon Deals

Top