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Misc F250 questions

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Old 06-02-2013, 09:25 PM
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Misc F250 questions

Hi guys, I have a 94, F250, 7.3 turbo, 4X4. It’s an early 94, thus some of the parts (exhaust) are still the same as the 93’s. This is mostly a parts runner/ work truck, several times a year it is towing 10’000lbs of trailer and tractor.
I am in the process of replacing the transmission (E4OD) and have several questions about it and some other issues I have.
The new transmission is from a Power Stroke, not sure of the year as the truck was burnt almost beyond recognition, but it was still the early body style, same as my 94. The main elect connector is slightly different from my old one that is mostly rectangular, the new one is a little more oval. So here is my first question, the wire colors do not match 100%, but they are close, can I assume that they will be OK as long as I keep the wire& pin arrangement the same as the original plug?
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Next question, leaking exhaust from manifolds to the turbo, is there any fix for the cast iron manifolds where they slip together? The flanges leak on the crossover pipe as well but I’m thinking about making some soft copper washers to go in here. If they leak a little I’m not going to lose any sleep over it but I would like to fix it while I have everything apart.
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Next question, sucking air into the fuel system. It sure seems to me that I am having this issue, when it sits for a little, it starts just fine but only for a second or two, then I have to crank on it for a while to get it started again, and then it surges and gallops for a few minutes till it gets the air pushed out through the return. Sometimes when I am idling along (down the lane out to the field) it will start to surge, as if the fuel pump can’t return enough to keep all the air out. When running down the road it seems fine. It has a new fuel pump, I replaced the Schrader valve on the filter housing, and can’t find any leaks anywhere. I had a 92 F350 that had the steel fuel lines under the cab rotted through but this doesn’t seem to be the case with this one. Anyone have a suggestion as to where to start looking?
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Thanks.
<o></o>
Pat
 
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