while the engine is out....

Howdy folks, long time no post ....

1996 f250 extended cab psd auto 4x4

I decided to pull the engine on my truck to hopefully make things a bit easier. I am hoping you guys can weigh in and make suggestions on what else i should do while its out, the truck has 180k, the transmission was new from ford 25k ago.

Here is what i have on the list so far:

oil pan gasket- ultra grey rtv
stainless bellowed up pipes
up pipe collector
ebpv deleted pedestal
ebpv flapper deleted outlet
turbo rebuild kit- going to wait and see what condition the turbo is in, though with 180k....
reseal intake manifolds
Banks technicooler kit
waterpump- like the idea of a international pump with a filter but not sure i need to mess with it.
transmission cooler- i purchased a cooler for a 99 that i now don't see fitting with the banks kit.
modify firewall to make space for 3" downpipe
4" exhaust
Air filter- truck currently has a K&N and i have recently read that these are not ideal for the PSD, suggestions?
flush coolant- once i flush the system whats the best coolant to use?
new glow plugs- oem
rear main seal a good idea?
any other seals or gaskets that i would hate myself for not doing?
was thinking of pulling the injectors to have them checked out...

what am i missing......

thanks in advance

and because everyone likes a post with pictures...


and here's the other project:

Turbo rebuild: get the 360 bearing upgrade.
I would skip the banks intercooler. Just get one from a SD.
Intake plenums: I would just replace with billet.
Water pump: do the IH one.
Dump the k&n for a 6637, or if you don't like the look, get a s&b.
Fleet charge.
For the main seals, it seems best to leave them alone if not leaking.
Do UVCH'S and gaskets. Motorcraft only.


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Already have the banks kit

do you have the billet plenums? who sells these for OBS trucks with stock turbos?

also, what's your feeling on the water pump swap? my understanding is that it will require some plumbing changes. what is the international part # on this pump?

Ah, then run the banks kit. Lol or sell it and buy the sd cooler.
Don't have the billet plenums yet. RiffRaff would be where I would get them.
Diesel site has the water pump. They've already modded it, and comes with new bolts, etc. For your year, it's a bolt on. My 94 uses the idi style radiator, so it requires some changes.

Or you can just get a plain old replacement pump, and add in a coolant filter to the heater lines.
I just like the IH one because if you need to change yours anyways, it's two birds with one stone.

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Its says on the riff raff site that those billet plenums are not compatible..... bottom of the page

Ah, duh. It's because the inlet is bigger to match the sd style.
Still would work, since you're not using the stock intake y from the turbo. Just may have to change the boots, if you went that direction.

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You may want to replace the o-ring between the dipstick fixture and the oil pan. That is a common leak point.
Also, you may want to replace the injector o-rings if you are pulling the injectors out.

Re: the SD plenums, they are an interference fit with the OBS turbo & pedestal. The SD plenums can be made to fit with some hammer love.

You might want to check my Project Parts Truck thread:
http://www.oilburners.net/forums/showthread.php?74824-Project-1997-Parts-truck

Day one

day two and i have some questions....

I really want to do as much as i can afford to ensure i don't have to pull this beast again anytime soon
Looking at the exhaust manifold and bolts has me thinking something needs to be done. whats the best way to upgrade this situation?
One thing i read was a guy that used stainless studs with aluminum bronze nuts?
Dorman aftermarket manifolds having a reputation for cracking,Ford is the best manifold option?, . is there another option?

i am pulling the injectors to send off to conestoga diesel, would like to replace all related parts, valve cover gaskets, harnesses glow plugs... i need to make a list



and for more experienced eyes, my turbo wheels

Wheels are worn. Wouldn't say unusable though.
For the UVCH'S and sensors, just know Motorcraft only.
Haven't really heard much on the dorman exhaust manifolds. You can get some like headers from other aftermarket companies.
But if they weren't leaking, again I'd leave them alone.

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You don't have to go all wild over the nuts and bolts. Stock items work just fine. Clean them up and reuse then. I would only use ARP Head Studs. They are the best.

DaveBen said:

You don't have to go all wild over the nuts and bolts. Stock items work just fine. Clean them up and reuse then. I would only use ARP Head Studs. They are the best.

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awww you must be from a place outside of the northeast rust belt of doom. re use bolts.....

trip to Harbor Frick and the always awesome Woodwards hardware and i picked up a "rated" 1 ton stand and 4 130mm M12x1.75 bolts with washers.

it doesn't totally fill me with confidence... but i think it will hold.

SD heads and pre 97 heads are the same casting.
a couple of years ago I did a head swap and used 96 heads on my 01, when I set them side by side, there was virtually zero difference.
if youre gonna run an inner cooler with the SD stuff, they will be perfect.

I would also re-seal the oil cooler whole its out.

IDIoit said:

SD heads and pre 97 heads are the same casting.
a couple of years ago I did a head swap and used 96 heads on my 01, when I set them side by side, there was virtually zero difference.
if youre gonna run an inner cooler with the SD stuff, they will be perfect.

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forgive me but i am not sure what you are getting at?

IDIoit said:

I would also re-seal the oil cooler whole its out.

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this is in the works

metalminded said:

forgive me but i am not sure what you are getting at?

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the plentums will work without the stock turbo and Y