TECH folder
 

This is the Ford V10 6.8L Tech folder.

Please read the "Taking submissions for the TECH folder" and post your suggestions for links to threads with pertinent information.

Wondering why your MIL doesn't come on? Or in other words, wondering why your truck doesn't have an O2 sensor after the catalytic converter or a bunch of other weird things, like why your state can't do an emissions inspection?

https://www.ford-trucks.com/forums/5...t-come-on.html

Changing exhaust studs, removal of broken ones, etc

https://www.ford-trucks.com/forums/8...t-it-info.html

My own thread about removing studs and installing eBay headers:

https://www.ford-trucks.com/forums/s...d.php?t=593174

Thread on y-pipe, and lots of comments from people who actually did it:

https://www.ford-trucks.com/forums/6...h-results.html

And more y-pipe threads to read:

https://www.ford-trucks.com/forums/4...s-y-pipes.html
https://www.ford-trucks.com/forums/6...t-flutter.html

Clean your MAF

https://www.ford-trucks.com/forums/s...=1#post8490555

For pictures of MAF removal and a procedure, look at the Volant CAI install thread at:

https://www.ford-trucks.com/article/..._F250_V10.html

Volant CAI installation on a 2-valve 2001 V10:

https://www.ford-trucks.com/forums/7...-2001-v10.html

Superchargers:

https://www.ford-trucks.com/forums/5...g-whipple.html

A 3V in a 2V truck:

https://www.ford-trucks.com/forums/8...ue-solved.html

Synthetic oils:

https://www.ford-trucks.com/forums/8...hetic-oil.html

Replacing a V10 - lots of great info about E-series vs. F-series engines, 2-valve

https://www.ford-trucks.com/forums/9...2000-f350.html

A note about 2004 and 2005 2-valve PCV valves and gas mileage

https://www.ford-trucks.com/forums/9...cv-valves.html

Hedman header install, thanks to ak-angler :-X22

https://www.ford-trucks.com/forums/1...ll-w-pics.html

Some great COP info, from devongarver

http://mustangforums.com/forum/6314454-post1.html

The perennial plug-change discussion thread.

https://www.ford-trucks.com/forums/1...ead-heads.html

FUEL mileage polls:
 

Highway MPG poll: https://www.ford-trucks.com/forums/4...-mpg-poll.html

Combined MPG poll: https://www.ford-trucks.com/forums/4...-mpg-poll.html

Towing MPG poll: https://www.ford-trucks.com/forums/5...-mpg-poll.html

Spark plug thread and factory procedure changes.

After much hemming and hawing, I have decided to put this info in the tech folder. This is from a document that Ford provided to the NHTSA a few years back in 2005 in response to an investigation that was closed by the NHTSA because it was not deemed a "safety" issue. It was reviewed again in 2007 and again deemed to not be a safety issue because of the number of complains (total of 652 by 2007) versus the number of engines total (over 10,000,000).

My review of documents related to this (which I won't include here) show that after the model-year 2002 changes to a long-thread head, the 2003-2004 model-year shows a substantial reduction in plug blowouts. Of 652 complaints, NONE were shown to cause any damage to the hood, cause a fire, or a gas leak of any kind. Stalling was possible but again in very rare cases, and a restart was usually possible except in ONE case.

Running spark plug changes:

December 1996 - 4.6L 4V alignment feature added
February 1997 - 4.6L 2V head alignment feature added
September 2000 - WEP (Windsor Engine Plant) 2V head alignment feature modified (4.6/5.4/6.8)
November 2002 - WEP introduced long thread heads on 2V (all)
May 2003 - REP (Romeo Engine Plant) introduced long-thread heads on 4V 4.6 and 5.4
November 2003 - REP introduced long-thread heads on 2V and modified alignment feature

In 1999, and 2001, an interim fix was done for a cross-threading issue.
Original process:

Step 1 - Zero torque spark plug (air tool)
Step 2 - Torque to 16-20Nm final torque (DC Run down), monitor at 6-12Nm, and final torque must be reached within 0-360 degrees.

New process (addressed the possibility of applying installation torque for more than 25 degrees of rotation)
Step 1 - Zero torque spark plug (air tool)
Step 2 - Torque to 16-20Nm final torque (DC Run down) start monitor at 6-12Nm, and final torque must be reached within 3-25 degrees.

Another action to address cross-threading was the addition of an alignment feature to lead the plug into the hole.

AFTERMARKET PART NUMBERS AND TECH INFO
 

Whipple supercharger belt part #'s, thanks to green250

whipple belt part # - Ford Truck Enthusiasts Forums

Blown plug fixes
 

An excellent Timesert how-to with pictures, by tmehrkam

https://www.ford-trucks.com/forums/9...th-photos.html

Nominated for the tech folder by Wolfboro - THANKS!!!

How to quickly tell if an engine is a 2 or a 3-valve V10: https://www.ford-trucks.com/forums/1...ifference.html