MPatty
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I bought this truck a few years ago. It's a 1993 F250 with a NA motor and 093 Turbo, ZF5. After driving for a few years I noticed a coolant leak at the back of the drivers side head...no signs of coolant/oil mixing just leaking. I decided that I was going to rebuild and as most projects go it spiraled into much more than I had planned....18 months later its back on the road.
This was my first engine rebuild and significant truck overhaul. I called around until I found a machine shop that knew what I was talking about when I told him a 7.3 IDI and immediately asked how the back two cylinders looked. While prepping to pull the motor I found a factory turbo motor in a junkyard. I pulled it to get turbo rods and have an extra injection pump and turbo for cores. I was hoping to rebuild one and just do a swap... but the cylinders didn't look great and I decided to rebuild the engine in my truck.
The machine shop pressure tested the block and checked out fine. He went 0.020 over on the bores and he did have to take some off the block. The heads were gone through and comp 910's installed. All the valves were in spec after decking the heads. The valves were replaced with ceramic coated valves. Because the block and heads were both shaved the piston protrusion was out of spec. I had the pistons shaved 0.010 and cerakoted with piston coat. The cam and crank were in spec and just got polished and balanced. All bearings and bushings were replaced. The machine work took about 8+ months to get back, but I was told that before I took it in. Some of that time was caused by going back and forth getting pistons cerakoted and waiting on parts after figuring out what needed to be ordered.
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I assembled the block with ARP studs, CDD modified head gaskets, and all new seals.
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Final engine assembly ended up with
CDD 130 CC pump
CDD Stage 3 Turbo with waste gate delete
CDD 3" downpipe
CDD modified headgaskets
0.020 turbo pistons
All new bearings/bushings
CDD glow plug harness
E-fuel conversion with Walbro GSL392
ARP Studs
Exhaust and crossover pipe were all cerakoted
CDD Intercooler
South Bend Stage 2 Clutch
While working/waiting on the engine I wirebrushed the chassis and POR15 the chassis. I converted to a single 38 gallon tank with soft fuel lines and a sump.
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