2002 F250 diesel - discovery and build thread.

[Curious Hound]

Ahhhh. There it is. Now, I'm doing a little cleaning.

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.

 

[scotts90ranger]

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.

 

[Curious Hound]

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]

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.

 

[Curious Hound]

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]

Run that number......




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

Might still be there...

 

[Curious Hound]

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.

 

[Curious Hound]

I'm back at it today. Driver side injectors and glow plugs out.

Yuck.

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.

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

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.

 

[Curious Hound]

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.

 

[racsan]

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.

 

[Curious Hound]

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.

 

[Curious Hound]

I received the Crown Jewel today.

 

[bobbywalter]

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.

Amazon.com: TU-15 Diesel Engine Compression Tester Kit - Hydraulic Gauge with Glow Plug Injector Adapters, Compatible with Ford Powerstroke 7.3L, 6.0L, 6.4L, 6.7L, Cummins, Duramax, VW TDI, Perkins, Tractors : Automotive

Buy TU-15 Diesel Engine Compression Tester Kit - Hydraulic Gauge with Glow Plug Injector Adapters, Compatible with Ford Powerstroke 7.3L, 6.0L, 6.4L, 6.7L, Cummins, Duramax, VW TDI, Perkins, Tractors: Fuel Pressure Testers - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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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]

I received the Crown Jewel today.

View attachment 102277

View attachment 102278

Hopefully she flys good for you. I loved mine

 

[Curious Hound]

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

Wow. Close tolerances.