I've found that my head gaskets are toast, and probably even egr cooler. So I'm order the complete system from Sinister - EGR cooler upgrade, oil cooler, ARP studs and new gaskets all around. Is there anything else that I should/have to get and replace while we have the motor tore down? Other washers, bolts that may break, gaskets, etc... I want to make sure I have all the correct parts when this "fun" project starts...

This is the package I've ordered:

Kit Includes:
•04-07 Upgrade EGR Cooler By Sinister Mfg. Company
•Ford Factory Head Gaskets either 18mm or 20mm by Sinister Mfg. Company
•Ford Exhaust Gaskets
•ARP Head Stud Set
•Ford Factory Oil Cooler Kit
•Ford Factory Oil Cooler Screen
•Ford Factory Intake Gaskets
•Ford Factory Turbo Hardware/O-Ring Kit

Ford 6.0L Powerstroke Complete Solution With Upgraded Cooler

From what I've read, my 2006 has a build date of June 2005, so I use the 18mm gaskets, correct?

Boy is this going to be fun..

 

Dont know if this helps but just in case you don't have the numbers yet this is the list I worked off to do mine. The oil cooler screen is included in the oil cooler kit.

3C3Z-6A642-CA Oil cooler kit
6C3Z-9T515-A UPDATED oil drain tube
3C3Z-9T516-A UPDATED oil feed tube
6E7Z-9A332-B UPDATED dummy plugs & stand pipe kit
4C3Z-9B246-F UPDATED STC kit w/ turbo gasket kit
3C3Z-9439-AA x2 Intake manifold gaskets
3C3Z-9433-BJ Intake manifold set
Coolant filtration system
oil
filters
coolant

 

STC fittings & blue fuel pressure spring.

 

Probably coolant filter

 

Thanks for the info - already have a Dieselsite coolant filter in place. What does the blue fuel pressure spring do?

Any special tools? I found that I may need an Injector release tool,injector pressure regulator socket and an oil line disconnect tool - do I really need the glow plug connector remover/installer (part 303-1114)? That looks so simple yet insane expensive!

 

If you are talking about the injector release tool for the connectors.. dont waste your money. A 12 point 19mm socket works perfectly. Also you will need a long-shank T40 bit to remove/install the injector hold down bolts and then to properly torque them

 

Thanks - I wont get that one - what about the Glow Plug Connector Installer/Remover - looks like a curved hanger on top and 90* fork on bottom - pretty simple - yet $$$$ to buy...

 

The glow plug harness removal tool does not work well at all. You can pull the harness using a piece of 16 gauge wire.

There is a ring at the bottom of each connector, wrap the wire around it then yank the wire with a pair of pliers. The glow plug is 10mm, just remove and reinstall.

I think it works better (before removal) to spray the connectors w/ WD40 and heat each one up slightly w/ a hair dryer or heat gun (don't get too close w/ a high power heat gun).

 

Excellent info guys - last question, do I really need to replace the oil drain and oil feed tubes to the turbo (top 2 above)? I'm ordering the STC and blue spring upgrades as from what I read that is a big step into extending the life of the injectors. But if I do not ruin the two tubes, are they really necessary. This job is getting real expensive real fast, and I'm wondering if another $200 is really worth it for two tubes...

 

I don't think you need the feed tube and I have an extra drain tube if you don't have one already. I can make you a deal on it. I have pics in my albums on the old drain and the updated drain so you can decide for sure.

https://www.ford-trucks.com/forums/m...ain+lines.html

 

Well, glad I looked. I already have the new feed tube that is the bolt on, o ring style (not the STC). So don't need that - and from the looks of the drain tube, I don't see a huge difference in size, so I think I'll probably skip on that - saves more $$ for coolant and oil....

 

Also looks like I've been using the WAY wrong coolant - Need ELC - My guess is something like Zerex ZXED1? Shows it meets Cat EC-1 specs? Trying to remember, how many gallons do I need and do I run it straight or a 50/50 with distilled water?

 

Maybe cleaning the turbo??

 

it was somewhere around january 20, 2006 that was the changeover
on head gaskets, i believe.

the only ugly part is still using the OEM oil cooler, but you knew that
already..... the BPD oil cooler solves that problem, but it's a chunk of change.

while i had the heads off, i had stellite valve seats put in and the heads
magnafluxed for cracks... but i don't want to have to revisit this, ever.

 

Cleaning turbo while its out - plus I know about the oil cooler - but I think with a fresh system flush, plus having my coolant filter in place and a fresh cooling system full of EC-1 coolant, it shouldn't be a problem...