Project Truck - 89' F250

laserjock

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The lines are 3/16. The fitting sizes are anybodies guess. Many possible combinations. Look at your rear line back to the rear brake hose too. They love to rust in two, right behind the cab.
 

renjaminfrankln

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Thanks! I did check that line and it looks to have been replaced at some point. I spent a good hour under there last night crawling around with a flashlight.
 

renjaminfrankln

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Replaced rusty straight pipe with 3” exhaust.

Still have a leak to chase up near the turbo.

This week - changed oil with 10-40 delo
Topped off rear diff... took 2.5 quarts lol
Changed fluid in ZF5 with mercron V
Topped up front diff and xfer case

Front and rear diff are getting geared to 3.55 at some time soon. Found a shop to do the rear for $800 and the front I’m going to buy a used 3.55 axle, replace the balljoints/ujoints and seals and bolt it on
 
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laserjock

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Replaced rusty straight pipe with 3” exhaust.

Still have a leak to chase up near the turbo.

This week - changed oil with 10-40 delo
Topped off rear diff... took 2.5 quarts lol
Changed fluid in ZF5 with mercron V
Topped up front diff and xfer case

Front and rear diff are getting geared to 3.55 at some time soon. Found a shop to do the rear for $800 and the front I’m going to buy a used 3.55 axle, replace the balljoints/ujoints and seals and bolt it on

Nice build.

I hope that price includes the gears. That’s pretty steep other wise.

I got to say I’m really on the fence about my 3.55 gears. I think if I still had my typ 4 cam in there I’d be a little better off but what I’ve found on my combination is to make boost in OD I end up being around 80 mph which is not optimal with the camper in tow. Then again my setup is pretty different than most.
 

renjaminfrankln

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Note the big dent in the driver's side door. I pulled it out this morning with a toilet plunger in about 2 seconds. Who knows how long it's been there.

In the next 2 weeks I am replacing the axle pivot bushings and having a transmission shop replace the flexplate and clutch with a solid unit (quoted $650 for labor, seems fair).

After that I am going to tackle my exhaust leaks. I have a pretty major leak at the driver's side exhaust manifold where the Y pipe connects, and another where the Y pipe connects to the pipe going up to the turbo. These leaks have gotten worse and i'm sure they are affecting my turbo's performance.

After that... its time for new carpet in the truck and sound deadening material. I have a bunch of noico 80mil left over from doing speakers in my daily driver.

New wheels and tires. The wheels are 16x7 AR Outlaw II with a 3.7” backspace. Tires are 265/75/16 Corsa Highway Terrain. I usually buy name brand tires but these were only $92 each so I figured what the heck. They are E rated.

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renjaminfrankln

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Pics coming later... new horn, got new headlights and tail lights in to replace the completely faded originals. If I get motivated enough this evening I may get a chance to buff the paint with a little polishing compound.

And following up on my last post, I did fix my exhaust leaks in the Y pipe. Turbo pulls much stronger now, and I enjoy the truck not sounding like a go-kart any more.

I ordered a replacement carpet for the interior in dark gray. It has some kind of EVA foam backing for noise deadening. That is going in this weekend. In addition to as much 80mil Noico sound deadening material as I can cram in there.

The hood has no insulation. I plan to degrease the underside and install 80mil noico deadening under the hood, along with a dynamat 3/4" hood liner foam that is meant to go on top of that stuff.

Any tips on getting the seat out and the carpet in? I'm sure I can figure it out, but any tips appreciated.

One more thing I plan to do is make sure the transmission and transfer case boots are good and sealed. When I got the truck back from the transmission shop this week, the transmission boot was loose in one spot, and the noise on the highway from just a slight gap between the seal and the plastic on the floor was ridiculously loud.
 
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renjaminfrankln

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Huge difference from all of the soundproofing. I also put 1" thick foam soundproofing on top of the factory floor liner under the dash (above your feet).

Don't have pics of this, but one thing that helped a lot was to put some of the 1" foam soundproofing in the transmission shifter boot area. I stuck it to the inside of the metal housing, so that it hangs out over the gap between the "pan" and the shifter. This is a huge gap where a lot of sound can come in, and the rubber boot alone over this big gap does not do a great job.

I'm actually going to poke around now and see if its worth taking the top part of the dash off to see if I can't cram some more foam soundproofing in behind the firewall.

The truck is so much quieter, I am really happy with it. Before, it was hard to carry a conversation in the cab. Now i'm chasing down wind noises from the door seals and an intermittent ticking noise from the speedo.

The seat is from a 1996 F150.
 

renjaminfrankln

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Here is a "Before pic" of the old seat and vinyl flooring


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