Does this look right? I doesn't seem right to me. I'm thinking the fuel lines are facing the wrong way. I noticed when I put it back together that there was a slot in the neck of the threads and a little tab on the sending unit with a arrow. I figured the tab went into the slot. after a bit of aligning the big nut everything went right together. Sliding the tank under the truck it looks like the lines are too short or facing the right way.

 

The lines on tank should face the frame/away from center of truck.

 

Got it running and let it idle until it got hot so I could re-torque everything. The radiator hose coming off the thermostat has a constant tension clamp on it. I am getting a leak from there or the gasket. Probably from sitting empty for months. Gaskets shrink back? Anyway should I replace the tension clamp with a worm clamp?

To make matters worse it has stopped charging too.

 

The t-stat housing is prone to rust and leak. Upgrade to a billet housing from Riffraff or get another stamped steel one like you’ve got. Replace t-stat gasket.

I only replace those clamps if they are rusted out. They are probably better than most cheap worm clamps. They have a more even clamping pressure and are significantly more ‘substantial’.

 

How can I check the alternator or can here be another problem? I see it was replaced once. Says passed on a sticker and 100amp.

I was always taught to keep hose tension clamps where the factory designed them. Especially on plastic necks or you will have a failure over time.

 

Take alternator to autoparts store and have them bench test it.

 

For the love of God...why does that turbo spool so fast?!? Jason, that is absolutely amazing.

 

.84 exhaust housing, 4+4 compressor wheel and plenty of fuel.

I’m putting the same size injectors in another truck next week but with KC S300 balanced assembly in stock turbo. Anxious to see how it does.

 

Me too..

 

Did some reading in my manual and on 02s there are fusible links that are sometimes a problem. doesn't say where they are located but gave a hint in a fuse box behind the glove box. also did some you tube watching and come to find out these 6th generation alternators are a problem child. In this video this technician says his customer has had 5 alternators in 150k miles. Some have carried a spare with them and changed every year, that's crazy! he has 2 solutions for the problem one is going back to a generation 3 alt. Is this really as big of a problem as he suggests? I'm wondering as mine has 174k and this is a reman alternator in there now that looks like it wasn't replaced all that long ago.

 

It’s gotta be the easiest alternator ever to change... Get a ‘new’ lifetime unit from your favorite autoparts.

Some have used the slightly bigger 6.0 alternator with simple mods or there are a couple of good upgrade aftermarket options.

 

I'm wondering if 110amp is enough output and overworking them till they fail. I'm thinking of 130amp may be better.

 

I don’t find the failure rate to be that high. More likely cheap parts in reman alternators that have a short service life.

But here is a popular high output option.

https://www.dcpowerinc.com/products/...8518228c&_ss=r

 

Back in October of 2017, I took on a couple of projects on the truck. New 160A alternator, Denso starter and AGM batteries. The following February I made some charging wire upgrades, which can be found at the link below.

Charging wire upgrades: https://www.ford-trucks.com/forums/1...energized.html

Quick Start 160A alternator details on FTE: https://www.ford-trucks.com/forums/1...l#post17800867

Quick Start 160A listing site: https://store.alternatorparts.com/82...lternator.aspx

Both projects/installs have been doing a find job since installing them. I almost went with a parts store 6.0L alternator, but decided to take a chance on this one since another trusted FTE'r had done the same thing just before me and was happy with the results. I also wanted to make sure that the brand new AGM batteries I bought had enough charging ability to behind them. Again, so far so good... But, anything made by humans can and will fail at some point...

 

Alternator is junk. It was only a 100 amp and I see the minimum is 110 for a single alt. Did some web searching and it's all over the place. Some say they came with 110 and others 130amp. I decided to check my build sheet and it says HUAACO Heavy Duty Alternator. Can' find anywhere what code means. Even in the tech folder there is nothing. anyone know or I'll check with my Ford dealer parts department.

If it's a 110 and I go to a 130amp will I need to upgrade the wiring? Again discussions are all over the place. This BD Electrical keeps coming up as having a 130amp for less the $120. Can't find any negative reviews ether. Just seems too cheap to me to be any good.