1999 7.3 van build thread


Even tho this is a large van, we are still cramped for space, so all extra space will be used lol.
Last night, I pulled the turbo off, and checked the up pipes. There was some oil in the pipes, but not enough to tell me 1 of the injectors wasnt seated. I cleaned out the pipes the best I could and put it back together. I restarted it and there was alot less oil leaking out. I let it idle for about 20 minutes, and by the time I moved it back into the garage, there was no oil dripping. Also, there was never any blue smoke out the exhaust.
I know they say that the diesels need to be run pretty hard for a bit in order to work the air out of the fuel and oil system, but I havent fully bled the brakes yet, and the rear fenders are not in my possession right now, and the front fenders are not attached fully, and there is no headlights in it yet....... wait, that never stopped me before....... boy my neighbors love me
It will be a little bit before it actually hits the road, so for now, idling will be good enough.
There is a few more things to tidy up, then it is onto the 2010 dash swap.
Steve S.
To many to list.
I have had a couple of projects that needed to be slipped in the garage, so the van progress slowed a little. Body work has continued tho, blocking out the rear fenders, and finishing the front fenders. The front bumper showed up yesterday, so that went on.
Its kinda hard to see with the low light.
We also started fitting the new tow mirrors.
And, we took it for a short ride last night. There are a few bugs to work out, but nothing major. It was nice to see it move again.

Steve S.
To many to list.

The last couple of weeks have involved wiring, and body work. The front and rear fenders are getting blocked out and ready for paint. We fit aligned all of the front body panels, and are closer to paint.
This weekend, the owner and I knocked out one of the last "big" projects. Saturday morning we started with this.
In less than an hour, we had this
In a little over an hour later......
Everything is a physical bolt in. The heater box on the firewall is the same between the 1999 and the 2010 dashes. The heater controls are the same. The passenger air bag plugs in. All bolt holes line up. The 1999 steering column bolts into the dash. It is almost scary how easy this part was.
Now on to the "fun" part. The gauge cluster. None of this is bolt in. The 2010 cluster uses the "CAN-BUS" electronics, while the 1999 is still analog. What I plan on doing is cannibalizing the 1999 cluster electronics into the 2010 cluster face. In my mind, this should work, now lets see if in real life it will work.
Steve S.
To many to list.
It is starting to look like a completed project. Headlights are mounted.
I have mounted up the TS controller and the 4x4 switch.
There will be some switches next to the TS controller.
Then there is the fun part. The instrument cluster. I have taken the 2 clusters apart, and I am going to start wiring things together soon.
Front and rear fenders are blocked out and about ready for paint. The van should be heading off to paint in the next few weeks. I wish I could paint this one, but I just dont have the room. A 9' tall van in a 10' garage doesnt give me any room.
Steve S.
To many to list.
We now have lights!!!
This is using the 1999 harness, with the 2010 dash switch, and the headlight plugs from the 2010. A series of relays were required to use the 2010 switch.
Steve S.
To many to list.
Got the air intake tract run, so the factory air cleaner housing is being used. It is a tight fit, but it does fit.
The tract goes up and over the intercooler tube.
I mocked up the hitch plate and it is currently being cut. The license plate area will be recessed into the plate.
Mounted the new door on the rear. As you can see, we shaved the license plate box off the door. We added the handle and lock hole from a side door.
Wired up the front spot lights. 7" LED.
Added a plug for the block heater. Nice flush mount.
Since the back door on the side of the van has been welded shut, we dont need the handle in the door jam, so that was shaved
Added Upfitter Switches next to the tuner screen.
And the owner did not want the brake controller just hanging off the bottom of the dash, I flush mounted it to the right of the steering column.
The silver screw head is to activate the manual brake control. This will be replaced with a nice black thumb pad.
Steve S.
To many to list.
Some minor tuning things to go over. It should be off to get a front end alignment later this week.
The van and what it will eventually be replacing.
Working on getting the 2010 cluster working.
Checking things as I add them.
Steve S.
To many to list.
Ford Trucks for Ford Truck Enthusiasts
The van sits just at about 8' tall at this point. The plan right now is for a full width, 12' long "safari" basket up top. It will be taller lol.
Steve S.
To many to list.
The hitch is made up and is getting welded.
All 1/2" plate. This thing shouldnt go anywhere.
The 2010 door panels slide right on. I have not done the wiring on the switches yet.
Preparing the van for paint. On the little tires.
And finally, some paint on parts.

Steve S.
To many to list.




