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  1. david85

    Fuel Selector Valve Overhaul

    Ok, time to start the final assembly. Here we see the actuator installed on the valve side of the case. This is retained only be E-Clips. The spare FSV that found had one of these E-Clips rusted apart. I'm still not sure if it was made of Stainless, or carbon steel, but need to be replaced. The...
  2. david85

    Fuel Selector Valve Overhaul

    Alright, so what are those other brass contraptions on the sides of this actuator? Those are the contacts for the internal switches. There's a switch on each side of the actuator that change states depending on where the switch is along it's range of travel. One set connects power to drive and...
  3. david85

    Fuel Selector Valve Overhaul

    If this were made today, there would probably be a software integrated chip on the FSV itself, and a brushless DC motor to actuate it. But since this was likely designed in the 70s, Ford had to use mechanical components to accomplish the task. First, is the linear actuator. The jack screw...
  4. david85

    Fuel Selector Valve Overhaul

    Once both valves are fully installed, it should look like this: You can partially test the valve by pushing down on the stem and seeing if it springs back to the middle position Don't try pulling up yet, or it will pop out of the case. The retainers can be installed using a socket wrench...
  5. david85

    Fuel Selector Valve Overhaul

    Here's the valve components put together. You can see the side port and the end port openings. These align with the ports on the main outer case. Remember that side port? Here's the hole it must align with on the outer case. If you clock this incorrectly, one of the ports will be...
  6. david85

    Fuel Selector Valve Overhaul

    The fuel selector valve (FSV) failed in my truck a couple years ago. I was able to repair it by taking apart two valve assemblies and making one good unit. In doing so, I thought it might be possible to make a good valve out of the remaining parts. Feedback from folks here told me that the...
  7. david85

    Fuel Selector Valve

    I'm in the process of trying to rebuild an original selector valve. Yes, I'm really that stubborn. I honestly don't see much wrong with the original design. Simple switches and no electronics, except for a couple of diodes. So far I've been able to find a motor on amazon that's compatible, and...
  8. david85

    ATS Turbo Oil Feed Leak

    I run a stainless braided line on mine. Tried making a hard steel tube and had a couple times where it cracked on me while far from home. Not often, but often enough. The OEM pipe is probably more reliable than what I made, however.
  9. david85

    Tachometer Troubleshooting

    I looked briefly online at tach sensors for those engines and they seem to all be mag sensors. Not much shows up for alternator drive, but it looks like those should be higher than 0.15V anyway. Ideally, I would hook up the tach to 12V power, then start feeding it an AC or Pulsed DC signal from...
  10. david85

    Tachometer Troubleshooting

    The sensor may not be outputting a high enough voltage for this particular tachometer (0.15VAC does seem low). I wouldn't necessarily expect a low reading for a low voltage. Variable RPM signal is from variable frequency, not variable voltage. If the voltage is below the minimum voltage, I would...
  11. david85

    E40D advice

    Overheating while going uphill could be from slipping converter clutch. This could be related to a bad RPM sensor, but I'm not sure that it's the cause. A bad RPM sensor can certainly make the computer think there is an issue and generate a code, but I don't think it can actually cause a...
  12. david85

    E4OD Won't move

    For anyone else wondering, the lack of reverse is usually a dead giveaway that something has gone wrong mechanically. Aside from harsh engagement, reverse should work normally, even with no electrical power to the transmission. In theory, the factory filter should protect the transmission from...
  13. david85

    Arduino Glow-plug Controller, Build & Walk-through

    Huh, looks like rockauto only had three 1115's left. Just bought them all. EDIT: although I do see listings on Amazon and other online suppliers. Never tried buying them local so I don't know how common they would be at you're typical NAPA or AutoZone.
  14. david85

    Arduino Glow-plug Controller, Build & Walk-through

    I realize this is still blasphemy, but I am running Autolite 1115 glow plugs, which are self regulating (bough from rockauto). Same set for nearly 2 years and no issues. Tested each plug for 60 seconds before putting them in the truck. Typically glow for 5 seconds in the summer and 20 seconds in...
  15. david85

    Arduino Glow-plug Controller, Build & Walk-through

    Ah...I miss bread-boarding. I'm interested in how this turns out. I have a solid state controller on the shelf but it won't work on my 6.9 IDI, especially since I switched to dual coil glow plugs. Would be nice to have automatic glow plugs because I want to add a remote starter eventually.
  16. david85

    Beware of crappy magnetic oil drain plugs

    Looks like the one my truck came with when I bought it many years ago. Never tried to pull the magnet out, but I typically do see about that much metal on it. Best I can figure, it's coming from the lift pump arm.
  17. david85

    Another terrible loss..

    I suppose I'm one of the late arrivals here. So sorry to hear of his passing. Russ was an invaluable part of the community and I bought many parts from him over the years. Still running one of his Torque cams in my truck. My condolences to his family and friends. Godspeed Russ.
  18. david85

    Bell housing dowel needed

    As mentioned, McMaster Carr is an excellent resource for precision items like this because they have accurate dimensions for just about every item they sell. A drill bit is likely to be too brittle, so I don't recommend using that.
  19. david85

    Best location for E4OD temp sensor?

    One more vote for TC outlet. Mine is just before the inlet to the cooler, so there could be some slight cooling along the cooler line. Most regular driving is barely enough to move the needle (scale starts at 100F). Slow climbing a mountain road showed me the value of using low range to control...
  20. david85

    2wd front ibeam axel swap question. NOT 4WD*

    Never had tire wear problems when mine was still 2wd. Everything was stock and well maintained. Only real complaint was how difficult it was to replace the kingpins. I will say that most shops had no clue how to align them though. So I had to check and adjust everything myself. The trick is...
  21. david85

    6.9 stalling for no reason?

    Some kind of diesel treatment would be a good idea. I also like to use ATF, since it's packed with detergents and can lubricate delicate parts inside the injection system. Typically, you would remove the fuel filter, drain or replace it, then fill it with an additive of your choice (straight...
  22. david85

    Turning radius--crew cab vs super cab

    The Dana60 style pitman arm is longer.
  23. david85

    Turning radius--crew cab vs super cab

    I installed the longer pitman arm with the donor truck when I converted to 4wd. Although, it looks like stock tires do allow for a tad more swing before hitting the leaf spring, if I can get a slightly longer one from a superduty (requires mod to fit the OBS era balljoint taper stud). Is it...
  24. david85

    6.9 stalling for no reason?

    Almost looks like algae contamination. Fuel will still be clean when you drain it out, but that reddish sludge will be all over the bottom of your tank. Not to mention, fouling your lines and filter(s). Is that residue hard and custy? Or is it soft and sludgy? (getting real technical here...)
  25. david85

    e4od, VSS and US Shift intermittent issue

    Have you tried reaching out to US Shift? It's been many years since I installed mine, but they were very helpful when I was first getting mine set up. Karl Baumann himself ended up helping me through Emails and a couple phone calls.

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