I have a 4.9 with 160,000 on it. Would it be ridiculous for me to try 4-6 psi without rebuilding it, using something like a 7.3 turbo or a GM 6.5 turbo,
could i get an mpg increase? it runs no problem, and it has mass air flow so I don't think it would be that hard(1996). We have all heard of the 4.9 maverick that wasn't rebuilt at 110,000. What should I anticipate, what would it cost, should i even consider doing this?

 

If you're looking for fuel mileage gains..... No. 4-6 pounds of boost is probably within the realm of possibility but the turbos you mention produce enough boost to blow the head off of your 300. A successful turbo motor is built around the turbo. It can be done but will not be cheap or easy. There is a lot more to it than slapping on a turbo and doing some plumbing.

 

You're better off going onto FordSix and checking out their turbo/supercharger forum. There's a few good posts here and you should use the search function to find those as well.

The older Chevy 6.5 turbo has been used a fair bit with decent gains. I think I've seen a 7.3 turbo used once but it is a pretty big turbo for this build. Supposedly the go to turbo for boosting a 300 i6 is an HX35 from an older Cummins 5.9.

Having a MAF equipped engine is a HUGE advantage as you can get a A9L ecu from a 89-92 Mustang and tune that. You'll have to learn to tune, so like firegod33 said it won't be just slapping a turbo and plumping it in.

As far rebuilding or not, I believe one guy ran upwards of 8-10 pounds of boost on a high mileage engine with some decent numbers but in the end he rebuilt it. After that he didn't update with results.

I've toyed with the idea of boosting my own truck after it's finished being build and then an RSK, just as the next logically step in tinkering
I've done some research but I'm sure someone will pipe up with more info or correct anything I may have been a little off on.

 

Thanks, I was not completely sure if I would have to tune it with a MAF, I'm just toying with the idea in my head. But I will continue to look into it

 

It's called a wastegate. Too big of a turbo won't hurt the engine,only make a less than good running combo.

 

7.3 turbo is too big. 6.5 turbo is barely big enough.
HX35 is perfect.
You would be good with 6psi. That will be a substantial gain with the 300-6.
Most people will tell you that you need a specifically built engine and expensive tuning to run boost, and depending on your goals, they may be right. But fortunately for you, you're not expecting that level of horsepower, so you're fine.
You don't need to swap computers, and if you have an auto trans, swapping ecu won't work anyway. You can use quarterhorse or tweecer to tune most every aspect of your truck.
Change injectors, bigger maf, and other supporting mods.

There are a few topics about this subject. Do a search and you'll find some useful info.