The 1990 F250 truck project that I acquired last September continues to be an interesting saga. In addition to changing all filters and lubricants, thus far I've:
1 - Replaced the lift pump
2 - replaced the fuel heater element in the filter housing (leak around boss for wire terminals)
3 - replaced the injector return system
4 - replaced the injection pump (Mini Moose)
5- replaced the heater core
6 - replaced the block heater
7 - replaced the windshield wiper motor and arm assembly
8 - replaced the clutch master and slave cylinders. Currently replacing the clutch linkage arm under the dash and adding a heim joint to the master cylinder push rod
9 - replaced the batteries
10 - replaced the starter with a gear reduction model
11 - replaced the alternator and voltage regulator
12- replaced the starter solenoid
13 - replaced all glow plugs
14 - replaced all belts
15 pulled a vacuum on the air conditioner (it's holding). For some reason the belt was missing from the air conditioning compressor. (found out why tonight - compressor is toast. New compressor, receiver/dryer, orifice and related switches on order for delivery later this week)
16 - replaced the temp sender
17 - Replaced the temp sensor for the injection pump advance
18 Replaced the headlight assemblies
19 Rebuilt the front brakes, replacing master cylinder and servicing wheel bearings.
20 - Replaced the engine oil cooler (That's why the truck was originally parked 7 years ago)
21 Sandblasted the rims and repainted with silver two part urethane paint with Michelin LTX LRE tires that I swapped from one of my wife's horse trailers. The tires only had around 5000 miles of wear on them but since they were six years old she wanted new ones. Worked for me!
Still need to:
Replace the windshield (scheduled for next week)
Replace the oil sending unit (second time)
Weld up floor pan by doors
Replace door and window gaskets
Install sound deadening material on firewall and floor board
Install a coolant filter
Install a trailer brake controller
Replace the hood release
Replace the bushings on the clutch linkage under the dash
Install the firewall brace for the clutch master cylinder
Rebuild the front end as needed.
Replace the turn signal assembly in the steering column
Lubricate the ignition switch linkage in the steering column.
TIG weld or replace rear housing on transmission where someone managed to break it at the mounting bolts.
Repair / replace the blown muffler. Surprisingly it's not loud at all - even with the bottom of the muffler blown out.
Check the rear brake status and replace the wheel cylinders (and shoes if necessary).
Build a new front bumper. I'm thinking of one of the weld up kits from Affordable Off-road. I'd like one that is flat on top so that I can stand or kneel on it for working on the engine, and w/o the cutouts in front and on top for a winch. I have one that is mounted to a receiver hitch that I can move from trailer to trailer (or in this case trailer to truck), so I'll add a receiver tube into the bumper.
Previous owner told me that the clutch pressure plate and disc had been replaced, so that's on less thing to worry about.
Going forward, I'd like to get a set of the GM mirrors that Complete Performance in Texas sells, along with the cup holder for the cab. The OEM mirrors leave a lot to be desired.
Long term I'm planning to mate the back end from a 1982 F350 dump to the front end of this F250. I need to source a PTO pump for the ZF5 transmission for this. Also need to figure out rerouting the exhaust so that I can mount the PTO on the passenger side of the transmission so it will line up with the pump location on the F350 frame.
Below is the pic from when I picked the truck up from the farmer who I bought it from. His uncle purchased it new in 1990 and used it to haul a camper all across the USA. Body is remarkably clean.
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Many thanks to all on this forum who have provided sage advice - either in direct response to some of my inquiries or in the archives (that I have spent a lot of time researching).
Scott
