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Crewcab Project

Discussion in '7.3L Powerstroke Diesels' started by catbird7, May 20, 2020.

  1. lotzagoodstuff

    lotzagoodstuff Supporting Member Supporting Member

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    Lots of wires on a PSD vs IDI for sure. 7.3 CCLB dually with a 6 speed is a sweet rig, I think it's worth the effort.

    One thing that I would pay a lot of attention to is any updates/differences between 99-03 that might effect the harness options. If you can identify the correct harness for your truck and confirm with a diagram, then try to verify what newer/older harnesses differences are, it will help your search. I think you can still get a brand new engine harness from Ford and although it seems expensive, having all new wires/plugs/clips has it's advantages.

    Good luck and hang in there. Harnesses/interior work is tedious and detailed, but organization and taking your time should pay off in the end.
     
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  2. catbird7

    catbird7 Full Access Member

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    I found a used harness on eBay that has same pn# except one digit. After questioning the seller, it appears both trucks were same other than his was as auto. He wants $500 for the used harness. Ford parts lists the harness as obsolete, I cannot locate any nos ( new old stock). Here's couple more pics. IMG_0481.JPG IMG_0477.JPG
     
  3. catbird7

    catbird7 Full Access Member

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    Here's the BD turbo. Wheel turns smooth, not sure what would be required before reusing??? I'm planning to use stock turbo when I reassemble the truck. This turbo might go on later after bugs are worked out. IMG_0485.JPG

    IMG_0486.JPG
     
  4. catbird7

    catbird7 Full Access Member

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    After weighing all the information, all of the options, i think the best direction for me is installing everything from the single cab and modifying the wiring to power the rear doors and power seats.
     
  5. Oledirtypearl86

    Oledirtypearl86 Full Access Member

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    Make sure to solder all splices I used butt connectors on a project and it was a dirt road runner and I ended up redoing it 2 months later due to all the vibration
     
  6. lotzagoodstuff

    lotzagoodstuff Supporting Member Supporting Member

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    What he said above. Solder and marine heat shrink, the stuff with the meltable adhesive on the inside.
     
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  7. catbird7

    catbird7 Full Access Member

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    Firewall clean up has been a far bigger job than I anticipated. The heat compromised factory paint adhesion on just about everything.
     
  8. Oledirtypearl86

    Oledirtypearl86 Full Access Member

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    Poke it with a screw driver a few places make sure its not briddle and won't break apart when put into service
     
  9. lotzagoodstuff

    lotzagoodstuff Supporting Member Supporting Member

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    You could media blast it all if you really want it super nice. There's some folks out here who do mobile media blasting and it's really not as expensive as you think if you are just doing a specific area/panel and not a whole vehicle.

    You could also just DA sand everything that's reasonably flat, maybe get the rest as good as you can get it, and apply a liberal coating of POR or some other rust preventative coating and call it a day.
     
  10. catbird7

    catbird7 Full Access Member

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    I'm working at with a wire wheel on my hand grinder and recoating with por 15. This isn't the first time I've used por so you'd think I'd have prepared better by wearing disposable latex gloves, however the black splotches on my hands clearly indicate otherwise. I swear it doesn't matter how quickly you try wiping it off with a rag, it won't come off. It sticks like shit to a wool blanket!
     
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  11. lotzagoodstuff

    lotzagoodstuff Supporting Member Supporting Member

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    Agreed, I have POR on the list of things not to get on your hands right next to black walnut skins.
     
  12. catbird7

    catbird7 Full Access Member

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    Firewall clean up (both sides) is complete. Resprayed with duplicolor over the por15. Pulled crewcab outside and drove the donor / parts truck in. Amazing conditional difference between truck from Tennessee and a PA plow truck with half as many miles. IMG_0488.JPG IMG_0490.JPG
     
  13. catbird7

    catbird7 Full Access Member

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    Pulled the parts truck in and started harvesting! 18 years as a plow truck, she's really rusty
     
  14. catbird7

    catbird7 Full Access Member

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    I'm new to powerstrokes, and have a question regarding the glow plug system, why are there two different sized relays? One for gp, and one for intake heater. Is the larger one considered heavier duty and would it be beneficial to install two of the larger instead of one small & one large?
     
  15. catbird7

    catbird7 Full Access Member

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    IMG_0536.JPG IMG_0540.JPG Cleaning and repainting parts. IMG_0536.JPG
     

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