my brother and i have been working on his 96 stroke, we did the 6637 mod and an exhaust, turbo back, we put the muffler in but we didnt see the results we expected.... no turbo whistle not much power gain, it has an e4od but it has been beefed up. he also has a weeping lift pump... maybe one of the power issues? im wondering if the muffler is killing the turbo whistle but it doesnt seem like it should with a 3" dp and 4" to the muffler and out. do we need to delete the muffler to get the whistle and more spool from the turbo? we are also thinking about a dp tune would do tw but dp seems to have more options for the price... any advice/help would be wicked. thanks brothers....

 

no fuel, no spool.

 

I would take out the muffler if your looking for louder. Also doing an intake, and exhaust won't really give you much more power, just allows the engine to breathe better. As far as the chip goes, There are plenty of choices, if your set on DP then cool...IMO, I would go with a tuner who uses a TS style chip, You have more options as far as switching tuners if you want to try something else. If you go with DP, you will be stuck with their tunes unless you get the new F8 chip.

I would suggest getting gauges on the truck before you chip it. You need to keep an eye on temps. At least an EGT guage.

 

and TRANS temp!!

 

I'm going to clean up the valley tomorrow and run a UV dye in the fuel to find all my leaks without having to replace unnecessary parts. I'll update when I figure things out.

 

My truck was quieter without the muffler. Weird. It whistled like a deuce and a half just by dong the 6637 though. Before I did the exhaust. Do you know your boost pressure?

 

Not sure if it has any boost, no spool up, no whoosh, no whistle, no nothing.

So I ran the dye through yesterday, turns out it was leaking worse than I thought.

I purchased a new pump and all applicable hoses and banjo washers and a new filter. Tore into the valley starting with the fuel bowl. It had about an inch or more of sludge in the bottom! I cleaned all that out and found the heater element was toast, not a problem.

Next I started on the pump. Easy right? Yeah you'd think so... only two 10mm bolts and a banjo bolt... I stripped one of the 10mm bolts with a 12 pt socket (the only one I had), so I borrowed a 6pt and stripped it even worse. Tried pounding a 3/8" 6pt onto it, no dice, cut a slit with my dremel and tried a flat screwdriver bit, bent the bit, tried the 3/8" again and it worked because of the slit... (good to know for later).

Next was the banjo bolt: I didn't have the 1 1/4" wrench required so I had to maneuver the pump enough to get a big crescent onto it. In order to do that I removed a hard line fitting from behind the turbo. Oops... I got everything back together and then couldn't get that fitting back together. It just won't thread back on! I worked on it for 2 1/2 hours last night and had to quit. I guess the next step is remove the turbo to get better access.

Any Ideas?

Just remember don't remove anything you don't have to and get the right tools the first time! Lesson learned.

 

LOL. You can never work on my truck.

I have a Harbor Freight shop near me. I am not a big fan of cheap Chinese gear, but even if you don't have much money, you can pick up some cheap tools to do things right. That's how I did my pump when I noticed it needed a very large wrench that I didn't have. Friend's have borrowed that wrench set since. You only need it for a few jobs, but it's good to have.

It was too long ago to give you advice on the bolt other than if you are frustrated, walk away to calm down and then give it another go. Late night work lends to the frustration, but can't always be avoided. I don't remember having any significant problems getting it back together. You should not need to remove the turbo. If others have done it here, you can do it, too. Have confidence in yourself. Have you searched here for the procedure? It should be here. You can check PSN and DS, too.

Good luck!

 

I would loosen everything back up and start the fitting first then tighten everything down. They sell sockets that will extract a rounded bolt, I don't know what they are called but they work great. I will do a search later and if I find them I will post them here for you...as far as the lesson learned....it is a hard lesson. I know....I re-learn that lesson a few times a year, lol
Welcome to FTE!

 

Found a coupla posts on DS:

1996 Fuel Leak- Pictured - Diesel Forum - TheDieselStop.com

replace fuel pump - Diesel Forum - TheDieselStop.com

 

I did the fuel pump job. Trust me, I wanted to kick the guy in the nuts that thought putting the pump back there was a good idea. Apparently Ford figured it out in 99 and went to electronic fuel pump.

Be that as it may, when I put the thing back together, it was not easy. I had to keep all of the pump retaining bolts loose and wiggle it around (rotation and a little up and down) until I got the large banjo bolt threaded. I did not remove any of the turbo assembly, but I have fairly small hands.

It's been a few months, but if memory serves, it helped having a 1 1/4" socket to hold instead of the bolt head because of the angle. There was quite a bit of cussing getting it back together.`

 

Never learn? The 2008(ish)+ you have to pull the CAB to get to it! We are lucky, huh?

 

I guess they figured people would just get new trucks sooner than having to replace anything? yeah... right...

Just so we're clear: I'm talking about a 9/16" compression fitting hard line coming from the banjo and going up under the turbo and connecting into the back of the driver's side head. I can't get the rubber washer to squish enough to allow the nut to thread onto the fitting. I'm thinking possibly cutting part of the rubber washer? It's about 3/16" wide.

I'm anxious to see how much this fuel valley overhaul is going to improve my truck.

 

My brother and I got it figured out this morning. Turns out I had boogered the threads when I initially tried to put the fitting back together. Luckily the 45* brass elbow was easily removable and I used some very large wire cutters to clean up the threads on it. I also had to find a replacement rubber o-ring because the old one was toast. A trip to the stealership and I was good to go! Truck has more power now and shifts amazing compared to before, but the turbo still doesn't do the classic whistle. It makes a woosh when letting off under boost, but I can barely hear it spooling up. I wiggled the shaft and spun the impeller and there was no slop. I guess I can live with a non-whistle truck unless there's any other ideas?

 

Glad to hear you are running again!
What kind of air intake do you have?
Also have you put in a new down pipe yet?