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The people have asked for an update so here it is! Unfortunately I have not made much progress on the 04 as i wanted recently. Work got crazy over the past 8 months and i was traveling a ton. Naturally the few weeks i was home I didn't touch the truck because i was spending time with family or catching up on past due house maintenance etc. that being said i am home for a little while and my work travel will die down considerably. I have been going over what i need to do still and accessing what is worth doing myself and having done. One thing i have made a definite decision is to abandon the cummins swap. It is complicated to register in MA and i have a new plan...more to come (id insert an emoji but I've been gone so long i cant figure it out!). Below is my current list of whats left:
5.4l Motor:
- been sitting for 5 years now...damn thats depressing... thinking it should get rebuilt and i would have this done by someone. am i crazy? it has 104k on it which is low IMO. Transmission:
- same thinking as the motor and it was a plow truck the first 64k miles which makes me think either way its time, I'm wrapping the xfer case into this as well. Interior:
- Remove headliner an reupholster 08 liner
- Pull dash and solder remaining wires
- Rebuild subwoofer box (I may be older now but i cant get rid of them now!)
- Wrap up any dash finishing touches such as: mounting guages, center console swap, montecalvo edition lights, mount the fuse panel, etc. Front end:
- pull front axle and repaint, lube, new diff cover, dual steering stablizer, tie rods, balljoints the whole 9 yards
- DIY front off road bumper with: Winch, LED bar fogs, LED bar spot lights
- 30" LED bar behind grille
- Paint chrome grille surround gray
- Rebuild or replace front drive shaft
- New brakes and calipers Rear End:
- Tighten up all bolts, install and drill holes for uninstalled hardware
- New shocks (front as well)
- new calipers
- Attach bed supports to bed (bolt in solution)
- figure out fuel system...the Ex tank i am thinking of using as a transfer tank to the original front tank and putting the front tank in as well.
- Run wiring
- run brake lines
That is about it...i did miss a few things such as exhaust and replacing some engine accessories like the PS pump etc but those are the major projects i still have left...We will get there dont worry! Although i have been gone for a while I have still been busy...
So what have i been doing the past year or so...well...i cant recall if i have shared this here or not but back in May of last year i sadly traded in my 07 Expedition. She was up around 165k i believe and rust was setting in bad and parts were starting to fail regularly. With all that and my travel schedule i was left with a car that i was getting fixed or fixing myself almost every waking moment i was home. I needed the reliability more than the convenience of and SUV and so i made the decision to sell her and get an 2016 Charger R/T. Sadly I have just had a streak of bad luck this past year and after owning it for just two weeks i got backed into and my bumper was all scraped up...long story but didnt fix it unfortunately...now fast forward to march of this year. I took the wife into Boston to go to a seminar and when we walked out...I found this...
That had to be the absolute worst day of my life lol...at least thats what it felt like and this was my first New car purchase I've always bought older used cars in the past. After 6 weeks I just got her back 3 weeks ago and i changed a few things while she was under the knife! I ironically had been buying OEM hellcat bumpers and picked them up literally 2 days before the accident so what you see is all OEM hellcat bumpers from wrecked cars and i added Scatpack fog lights and a rear painted "diffuser" to the rear bumper. I also had the mid mufflers deleted and tips welded on after the repair and she sound mean! Next steps will be front splitter, black rims and maybe a small drop to get rid of some wheel gap. All the work was completely covered under insurance, it may have been a hit and run and they never found the guy but it worked out in the end and my rate didnt go up! Every single panel except the passenger doors and fender was removed and repainted or replaced do to damage.
I JUST drove home my new to me 1995 F250 7.3l ECLB with 198k for $1000 complete it also has an 8' fisher plow! Now it was $1k she is a little rough but in all honesty it is in MUCH better shape than my 95 F150 SCSB i had which i loved but couldn't fit well being 6'6" and driving a stick i barely could hit the clutch. It will need cab corners but mostly everything else is solid i can get new doors and a new bed fairly cheap around me that are rust free and that would just leave the cab rust that needs to be tended to. This is where the 12v and alison will end up, shes going to be a work horse to get all my other projects done and when her time comes...oh were gonna have some fun! Some initial thoughts were to SAS this with the 04 axles and get coil 05+ axles for the 04 but i am undecided still and the Dana 50 TTB is in rough shape so the decision should be made soon, i dont want to dive into too much detail and this will be its own thread...been thinking about just recording videos as well and posting them to youtube but I'm not much of a personality lol we will see.
On the drive home the plow joystick fried so i could not lower the plow...that was my job today was to get that thing lowered and off the truck so i could go get an inspection and not leave the suspension holding that weight for weeks. Had great success and she is freed up and ready to get registered, inspected, and cleaned on Monday! Believe it or not the trash was about to be a deal breaker for the seller, it was take the truck and trash or dont take anything...and there was much more than in this photo it was all scrap wood so i burned it last night lol. Also this looks like a fifth wheel frame there's one of these on each side any ideas? I tought it was part of the trash when i was looking at the truck.
Sucks about the accidents, but sure did work in your favor.
SAS swap on a 80-96 is pretty intensive isn't it?
Have you compression checked the 5.4? Don't see the need for a rebuild if it can just be sealed and lubed up. Same for the transmission, maybe an inspection rather than full rebuild.
For the Excursion tank, can you set up like a Transfer tank, or like the OBS trucks with dual tanks?
They did indeed, luckily I wasn't in the car for any of them. Apparently people like to hit it when I park it places.
SAS isn't too hard from what I've read back when I had my F150, PMf makes hangers that adapt to the SD springs so I could literally roll the axle across the driveway under the 95 and bolt it up. Track bars and steering are from what I remember just adding drop brackets for a lift and attaching them. The drive shaft is the tricky part having to change the xfer case yoke.
I haven't done anything yet with the 5.4 or the trans. I'll have to do a compression test on the motor, for inspecting the trans did what would I inspect other than clutch packs? I could always have it inspected by a shop as well I guess. The motor and trans I'm on the fence about doing myself because they are more important than the dash looking pretty lol.
Also any suggestions about separating the trans from the motor? I can't get the starter out or the flywheel to turn so I can unbolt the torque converter.
I was thinking dual tanks like the OBS setup and I have a second fuel gauge for my overhead console already. I have no idea how to plumb that though or how I would fill the rear tank. Initial thoughts were to put an electric tee in the filler neck with a button to switch from filling front to rear. That's easier than installing a second gas cover on the bed somewhere.
That had crossed my mind... is it worth the extra two cylinders though? Never owned or driven a v10 truck and I haven't researched the differences much. From what I remember it's fairly easy you need the motor and a v10 PCM. I'd imagine it's more complicated than that but from the little reading I've done a long time ago that's what I can recall.
The v10 should be pretty much that easy, just need to find a donor truck that has the engine bay harness, pcm, and belts and pulleys etc. exhaust Y pipe is different. But the power difference is night and day with the fuel economy not really going any lower than with the 5.4
If you swap Engines, order headers and tunes. Good header sets come with a y-pipe. The 5.4 transmission is the same housing as V10 but something about the internals is different.
Hey Guys, so ive got a dilemma right now and i want some input. the 95 F250 needs a new front end and I was to SAS it. I found a 96 F350 front axle for $650 and when i do thjis i was goong to run the front SD leafs from my 04 becasue the 04 is getting 4" lift leafs. But...I got a line on 08 coil spring axles with 3.73 gears for $1200 so i could convert the 04 to coils and on the 95 just roll the Dana 60 and matching rear axle from the 04 under the 95 and call it a day.
There are obviously a ton of conversion parts needed and i have the list made for both conversions but what are the thoughts here...
$1200 and coil convert the 04 and SAS the 95 (bonus is both trucks will have the same bolt pattern and can share rims)
$650 just SAS the 95 with a 96 axles.
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