6.0L Power Stroke Diesel 2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van

Love my '06 PSD; should I fix the rust?

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Old 09-16-2017, 12:25 AM
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Love my '06 PSD; should I fix the rust?

Hi All

Been a while since I've posted... I love my '06 F250 PSD AKA the "Brown Beast". Most reliable towing truck ever, I can tell what she wants by the way she sounds (and sometimes by the OBD codes), I can change the filters and oil in my sleep, but, she's starting to rust, diesel is more than gas, and I'm starting to get tired of the 'work truck' ride.

Have replaced the oil cooler, done an EGR delete and have a K&N intake... should I spend the money to fix the rust and put up with the ride? Or is it time to look at a newer truck?

Thanks

/trill
 
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Old 09-16-2017, 12:43 AM
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It all depends if you want a truck payment or just looking to have a newer looking truck. You can update your front end to a 11-16, add the newer interior, and bed. BAM... new truck!!
 
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Old 09-16-2017, 08:30 AM
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Have you tried aftermarket shocks? I got Fox adjustable shocks for my Excursion and the ride is WAY better than stock...and that's with an all spring lift kit
 
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Old 09-17-2017, 01:06 AM
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Depends on how bad the rust is and where it is. Full on holes in the bed is no biggie as you can replace the bed, but rockers all the way into the cab are a different story.
 
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Old 09-18-2017, 08:48 AM
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I will have to replace my front fenders and drivers door this coming spring on my '03 but that is the only place I have any serious rust, fluid film has taken care of most other places very well. That said if otherwise mechanically sound I would repair any rust you can, a better investment in my mind. I would recommend however getting rid of the K&N air filter and going back to stock before you dust the turbo and possibly damage other internal engine parts, documented fact by many on the 'net.
 
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Old 09-23-2017, 08:31 PM
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Thanks so much for the advice! I put better shocks on a couple of years ago but it still rides hard, not so bad for me but not so great for granny, hubby or my groceries.

The rust was way worse than I thought, pulled the inside panels off, all four doors are rotten on the inside half way up, possible the paint is what is holding it together. The parts of the truck I could get at to wash regularly with a pressure washer, like the bed, bumpers, wheel wells etc. are in good shape.

I got some estimates on the body work and better shocks as I haven't the equipment, knowledge, or garage space... I was close to needing CPR afterwards.

So, much as I love Brown Beast II (BB I = '88 250 gasser) I think it might be time to go Ford shopping.

Thanks again!

/trill
 
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Old 09-23-2017, 09:56 PM
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Hard to get a K&N clean

Originally Posted by jetjockey99
I will have to replace my front fenders and drivers door this coming spring on my '03 but that is the only place I have any serious rust, fluid film has taken care of most other places very well. That said if otherwise mechanically sound I would repair any rust you can, a better investment in my mind. I would recommend however getting rid of the K&N air filter and going back to stock before you dust the turbo and possibly damage other internal engine parts, documented fact by many on the 'net.
Sorry to hear you have rust issues, too, I am not sure the door design on the mid-2000 is good from the start.

I agree there are lots of reports of problems with the K&N intakes. As you know a dirty filter is death to an engine. What I've found is that K&N filters are really, really, really hard to get clean, and the time between cleaning is half, or less, than what the manufacturer says, at least in my driving environment.

That said, a cleanable filter is an economical choice if one is willing to spend 45 minutes every four to six months elbows deep in a laundry tub, and dang she breathes easy with the clear airflow. I don't see improvement in city mileage but towing performance was noticeable.
 
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Old 09-23-2017, 10:36 PM
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My doors are rusting as well. Not as bad as yours, but getting there. I'll replace with doors from a newer year soon.
 
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Old 09-23-2017, 11:11 PM
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