BWST's F350 maintenance/upgrade thread
#1
BWST's F350 maintenance/upgrade thread
I've seen some of you do this type of thread to track your journey, and decided I'd like to do the same with this new-to-me truck. After having to sell the Big White Stupid Truck in 2014 (my wife's term of endearment for it), and rebuild my life from a job loss and a stretch of unemployment, the time has finally arrived to get back in the game. While not near what I had before, this truck will be a great project - something to continue learning on with all of you, from whom I've benefited with so much friendship and 7.3L advice over the years.
Details of this rig are in my signature. It has a few issues, but runs and drives fairly well. It will not be my daily driver now, so I can take my time working on it, which is nice.
2001 F350 Lariat 7.3L 4x4 CCLB SRW 4R100
Purchased for $15K+tax May 5, 2020 with 269,275 miles on the clock
Build Date: Aug 2000
May 25, 2020.....269,393 miles
-R&R Front Axle shafts, replace seals, right U-joint, needle bearing, stub shaft
June 5, 2020.....269,700 miles
Information starts at post #117
-R&R ICP Sensor
July 5, 2020.....269,790 miles
Information starts at post #119
-R&R GPR
August 2, 2020.....270,100 miles
Information starts at post #186
-R&R Belt
September 14, 2020.....270,250 miles
Information starts at post #226
-R&R HPOP Lines
December 15, 2020.....270,800 miles
Information starts at post #253
-R&R Sound system
Information starts at post #351
-R&R Door Weatherstrip
Information starts at post #477
-Install Block Heater Plug Mount
Information starts at post #625
-R&R Transmission Cooler
October 2, 2021.....272,900 miles
Information starts at post #627
-Rebuild Turbo
May 6, 2022.....275,600 miles
Information starts at post #778
-R&R Coolant
September 18, 2022.....278,000 miles
Information starts at post #824
-R&R Transmission Cooler Bypass
November 21, 2022.....279,000 miles
Information starts at post #859
-R&R Torque Converter
March 18, 2023....281,000 miles
Information starts at post #872
-R&R Mud Flaps
June 1, 2023....282,000 miles
Information starts at post #878
-R&R Water Pump Intake Elbow
September 22, 2023....283,500 miles
Information starts at post #931
-R&R Front Shocks
December 15, 2023....285,000 miles
Information starts at post #962
-R&R Radio
Details of this rig are in my signature. It has a few issues, but runs and drives fairly well. It will not be my daily driver now, so I can take my time working on it, which is nice.
2001 F350 Lariat 7.3L 4x4 CCLB SRW 4R100
Purchased for $15K+tax May 5, 2020 with 269,275 miles on the clock
Build Date: Aug 2000
May 25, 2020.....269,393 miles
-R&R Front Axle shafts, replace seals, right U-joint, needle bearing, stub shaft
U-joint, non-greaseable, Spicer SPL55-3X, Amazon $36.23
Axle, outer stub, Spicer 2002692, Amazon, $55.69
Bearing, needle, Timken B2110, Amazon, $10.59
O-ring, vacuum hub, Ford FB1Z-4A322-AA, Amazon 2@$6.30ea
Seal, outer axle shaft, National 710493, Amazon 2@$21.30ea
Seal, axle shaft, National 710413, Amazon 2@$3.26ea
Washer, axle hub thrust, Ford F81Z4228BA, Riffraff 2@3.68ea
-R&R Transmission dipstick tubeAxle, outer stub, Spicer 2002692, Amazon, $55.69
Bearing, needle, Timken B2110, Amazon, $10.59
O-ring, vacuum hub, Ford FB1Z-4A322-AA, Amazon 2@$6.30ea
Seal, outer axle shaft, National 710493, Amazon 2@$21.30ea
Seal, axle shaft, National 710413, Amazon 2@$3.26ea
Washer, axle hub thrust, Ford F81Z4228BA, Riffraff 2@3.68ea
Dipstick tube, transmission, Ford XC327A228AA, Riffraff $37.48
Dipstick, transmission, Ford F81Z7A020BA, Riffraff $19.32
-Install trailer charge circuit relayDipstick, transmission, Ford F81Z7A020BA, Riffraff $19.32
Relay, 5 blade, 12V, SPDT, Standard Motor Products RY116, Amazon $9.34
-R&R Turn-signal RelayFlasher, 5 blade, 12V, LED compatible, Novita EP27, Amazon $12.67
June 5, 2020.....269,700 miles
Information starts at post #117
-R&R ICP Sensor
Sensor, Injection Control Pressure, 97-03, Ford F6TZ9F838A, Riffraff $146.87
-Hutch/Harpoon Fuel Tank3/8" compression coupler, 1 ea
3/8" tubing, aluminum, fuel line, 6"
Filter, fuel, inline, 5/16", Wix 33972, Amazon $12.20
Hose, fuel injection, 5/16", SAE 30R9, 18", Dayco 80079, Amazon $11.00
Clamp, fuel injection, 5/16", 4 ea
-Reseal Fuel Bowl3/8" tubing, aluminum, fuel line, 6"
Filter, fuel, inline, 5/16", Wix 33972, Amazon $12.20
Hose, fuel injection, 5/16", SAE 30R9, 18", Dayco 80079, Amazon $11.00
Clamp, fuel injection, 5/16", 4 ea
1999-2003 Fuel Bowl Reseal Kit, #7-003, DieselOrings.com, $23.05
Filter, fuel, Motorcraft F81Z9N184AA, Riffraff $21.53
Filter, fuel, Motorcraft F81Z9N184AA, Riffraff $21.53
July 5, 2020.....269,790 miles
Information starts at post #119
-R&R GPR
Contactor, 12V, Trombetta 684-1241-212, Amazon $18.35
-R&R lower alternatorAlternator rebuild kit (includes regulator/brushes, slip-ring, rectifier, bearings) installed regulator/brushes only, 6G7796G, Rebuilderinabox, $50.21
August 2, 2020.....270,100 miles
Information starts at post #186
-R&R Belt
Serpentine Belt, dual alternator, Gates K081377HD, Amazon $51.13
-Transmission FlushATF, conventional Mercon V, Valvoline 6 qt box, Amazon 4@$14.79ea
-R&R EBP SensorSensor, EBP, 97-04, Motorcraft 4C3Z9J460A, Riffraff $89.41
-R&R upper alternatorAlternator rebuild kit (includes regulator/brushes, slip-ring, rectifier, bearings) installed regulator/brushes, slip-ring only, 6G7796G, Rebuilderinabox, $50.21
-R&R Front Stabilizer bushingsBushings, front stabilizer, pair, Moog K201615, Amazon Warehouse Deals $4.74
September 14, 2020.....270,250 miles
Information starts at post #226
-R&R HPOP Lines
HPOP JIC LINE, Driver side head, 99-03, Riffraff RDP-HPOP-DRVR $79.33
HPOP JIC LINE, Pass side head, 99-03, Riffraff RDP-HPOP-PASS $88.41
-Delete AIH and install PlugHPOP JIC LINE, Pass side head, 99-03, Riffraff RDP-HPOP-PASS $88.41
AIH delete tapped plug, blue, Riffraff RDPAIH-Blue, $12.97ea
-R&R Transmission Cooler LineLine, Aux transmission cooler, driver side, Dorman 624-466, Amazon $50.95
-R&R Air FilterFilter, Air, stock box, Motorcraft FA-1750, Amazon $18.18
-R&R Transmission Shift Tube clamp/bushingsKit, bushing/clamp, Dorman 905-110, Amazon $8.40
December 15, 2020.....270,800 miles
Information starts at post #253
-R&R Sound system
Headunit, ATOTO S8 Premium, Amazon $267.01
Speaker pair, 6" x 8", 2-way, 60W RMS, Infiniti 8632CFX, Amazon $60,00 x 2
Camera, rear, ATOTO AC-HD03, Amazon $49.13
Harness, Metra 70-1771, Amazon $7.21
Kit, solder sleeve, Kuject WT001, Amazon $8.99
-Install GaugesCamera, rear, ATOTO AC-HD03, Amazon $49.13
Harness, Metra 70-1771, Amazon $7.21
Kit, solder sleeve, Kuject WT001, Amazon $8.99
Gauge, EGT, 0 to 1600 degrees, Isspro EV2, R17021, Riffraff $153.99
Gauge, fuel pressure, 0 to 100psi, Isspro EV2, R17044, Riffraff $149.88
Pod, Triple gauge, Autometer 18017, Amazon $67.04
Kit, Snubber, 99-03, Riffraff R78828, Riffraff $9.99
Plug, gauge hole, 2", Riffraff R7614, Riffraff $4.96
-Install ProgrammerGauge, fuel pressure, 0 to 100psi, Isspro EV2, R17044, Riffraff $149.88
Pod, Triple gauge, Autometer 18017, Amazon $67.04
Kit, Snubber, 99-03, Riffraff R78828, Riffraff $9.99
Plug, gauge hole, 2", Riffraff R7614, Riffraff $4.96
Hydra PCM chip 7.3L, PHP-HYDRA-RED, Riffraff $299.00
Mount, Hydra, HYDRA-MNT, Riffraff $25.67
-Install Auxiliary Reverse LightsMount, Hydra, HYDRA-MNT, Riffraff $25.67
Slim 7" LED light bar, 12V, Online LED Store, ORZLEDLBR712-FL, 1 pair, Amazon $21.95
March 6, 2021.....271,200 milesInformation starts at post #351
-R&R Door Weatherstrip
Weatherstrip Kit, both front doors, Fairchild KF3043, Rockauto, $45.00
-R&R MufflerMuffler, 3.5", aluminized, "BTM", Walker 21470, Advance Auto $51.99
Clamp, 3.5", Nickson 517312, Advance Auto $5.49 x 2
-Install Front FloormatsClamp, 3.5", Nickson 517312, Advance Auto $5.49 x 2
Floormat, classic, tan, rubber, WeatherTech W19TN, Amazon $69.95
-Install Front MudflapsMudflaps, front, WeatherTech 11001, WeatherTech.com $39.95
-Install Battery MaintainerBattery Maintainer, 2A, 12V, Noco Genius2D, Amazon $39.95 (upgraded 3/5/2022 to Noco Genius 5X1, $63.11)
Plug Mount, 125V 15A, 16" pigtail, Noco GCP1, Amazon $23.41
-R&R Shift TubePlug Mount, 125V 15A, 16" pigtail, Noco GCP1, Amazon $23.41
Shift tube, linkage, bushings, Dorman 905-102, Amazon $29.95
-R&R Hood support strutsStrut, support, gas-charged, pair, Maxpow 113769, Amazon $21.69
-R&R Trailer ConnectorSocket, 7-way, Pollak 11-893P, Amazon $12.09
-R&R Rear CalipersCaliper, passenger rear, limited lifetime, Duralast 18-B4752, Autozone $63.19
Caliper, driver rear, limited lifetime, Duralast 18-B4753, Autozone $63.19
-R&R Vehicle Speed SensorCaliper, driver rear, limited lifetime, Duralast 18-B4753, Autozone $63.19
Sensor, vehicle speed, rear axle, Motorcraft F85Z-9E731-AB (DY-1123), ebay seller u-techcenter $19.79
July 16, 2021.....271,960 milesInformation starts at post #477
-Install Block Heater Plug Mount
Plug Mount, 125V 15A, 16" pigtail, Noco GCP1, Amazon $23.41
-Install Cooling DeflectorDeflector, bottom cooler, Ford F81Z-8327-AA, Amazon $37.41
-Install Exhaust Brake, GPR switchesMounting Bezel, END, RockerSwitchPros $3.00 x 2
Switch, SPST, red LED, V1D1-GCCB, RockerSwitchPros $16.50
Switch, DPST, red LED, VAD1-GCCB, RockerSwitchPros $28.00
Actuator, custom Exhaust Brake, RockerSwitchPros $12.00
Actuator, custom Glowplug Enable, RockerSwitchPros $12.00
Fuseholder, Inline, mini, Littelfuse FHM2BP, O'reilly Auto Parts $3.99
-R&R ThermostatSwitch, SPST, red LED, V1D1-GCCB, RockerSwitchPros $16.50
Switch, DPST, red LED, VAD1-GCCB, RockerSwitchPros $28.00
Actuator, custom Exhaust Brake, RockerSwitchPros $12.00
Actuator, custom Glowplug Enable, RockerSwitchPros $12.00
Fuseholder, Inline, mini, Littelfuse FHM2BP, O'reilly Auto Parts $3.99
Thermostat, 192*, Motorcraft RT1201, Amazon $28.29
Housing, thermostat, billet, black, Riffraff RDPTSTATH-BLK, Riffraff $46.22
-Install Side Window DeflectorsHousing, thermostat, billet, black, Riffraff RDPTSTATH-BLK, Riffraff $46.22
Deflector, side window, in-channel, AVS 194953, Amazon $47.50
-R&R CAC BootsCAC boot kit, black, Riffraff RDPABK9903-Black, Riffraff $149.94
September 2, 2021.....272,400 milesInformation starts at post #625
-R&R Transmission Cooler
Cooler, 6.0L Trans, 31 row, Dorman 918-216, Amazon $186.01
Adapter, 1/2"ID to 3/8" ID, barbed, brass, Joywayus JWBTYZ08-12, Amazon $5.99 x 2
Hose, Oil Cooler, 1/2" ID, 150psi, 12ft, Hayden #112, Amazon $16.51
Adapter, 1/2"ID to 3/8" ID, barbed, brass, Joywayus JWBTYZ08-12, Amazon $5.99 x 2
Hose, Oil Cooler, 1/2" ID, 150psi, 12ft, Hayden #112, Amazon $16.51
October 2, 2021.....272,900 miles
Information starts at post #627
-Rebuild Turbo
Kit, GTP38 360 rebuild, RDPGTP-360,Riffraff $76.38
Up pipes, bellowed, w/ collector, eBay (first.racing) $67.99
Exhaust wrap, 2" x 50', ARTR-2-50, Amazon $17.99
Compressor wheel, 7/7, billet, FTE, no charge
EBPV rebuild kit, Garrett 729519-0003, Riffraff $97.52
Plenum Inserts w/ 4 clamps, Riffraff RDPPRI, Riffraff $54.70
-R&R Front and Rear BrakesUp pipes, bellowed, w/ collector, eBay (first.racing) $67.99
Exhaust wrap, 2" x 50', ARTR-2-50, Amazon $17.99
Compressor wheel, 7/7, billet, FTE, no charge
EBPV rebuild kit, Garrett 729519-0003, Riffraff $97.52
Plenum Inserts w/ 4 clamps, Riffraff RDPPRI, Riffraff $54.70
Pads, Front, Yellowstuff, EBC DP41308R, FTE $N/C
Pads, Rear, Yellowstuff, EBC DP41603R, FTE $N/C
Rotors, Front, Motorcraft BRRF-103, $90.93 x 2
Rotor, LR, ACDelco 18A934A, Amazon $36.53
-R&R HPOPPads, Rear, Yellowstuff, EBC DP41603R, FTE $N/C
Rotors, Front, Motorcraft BRRF-103, $90.93 x 2
Rotor, LR, ACDelco 18A934A, Amazon $36.53
HPOP, 18.5* swashplate, Dieselsite Adrenaline, FTE, $(a generous deal!)
Core credit, HPOP, CNC Fabrication, -$150.00
IPR reseal kit, Motorcraft 14-007, Dieselorings.com, $13.76
Core credit, HPOP, CNC Fabrication, -$150.00
IPR reseal kit, Motorcraft 14-007, Dieselorings.com, $13.76
May 6, 2022.....275,600 miles
Information starts at post #778
-R&R Coolant
Coolant, ELC, gal, Shell Rotella, Tractor Supply $17.99 x 4
-Change rear differential oilOil, 75W-140, qt, Supertech $14.99 x 3
Gasket, reusable, Lubelocker LLR-F105, Amazon $22.95
Cover, finned differential, Dorman 697-725, Amazon $58.39
Cap Screw, 5/16-18, 1-1/4", SS, qty 25, Amazon $16.98
Washer, 5/16, split, SS, qty 15, The Hillman Group 2238, Amazon $3.98
-R&R mirror switchGasket, reusable, Lubelocker LLR-F105, Amazon $22.95
Cover, finned differential, Dorman 697-725, Amazon $58.39
Cap Screw, 5/16-18, 1-1/4", SS, qty 25, Amazon $16.98
Washer, 5/16, split, SS, qty 15, The Hillman Group 2238, Amazon $3.98
Switch, mirror, Dorman 901-319, Amazon $14.91
-R&R Belt TensionerTensioner, dual pulley, Motorcraft BT-50, Amazon $68.87
-R&R Brake SwitchSwitch, Stop light, Motorcraft SW5219, Amazon $21.82
-Paint chip repairPaint, touchup, Deep Wedgewood, Dupli-Color AFM0359, Amazon $12.00
-Change transfer case oilATF, Mercon LV, qt, Motorcraft Mercon LV, O'Reilly's $14.99 x 3
-Change front differential oilOil, 75W-90, qt, Masterpro, O'Reilly's $14.99 x 3
Gasket, reusable, Lubelocker LLR-D060, Amazon $21.95
Gasket, reusable, Lubelocker LLR-D060, Amazon $21.95
September 18, 2022.....278,000 miles
Information starts at post #824
-R&R Transmission Cooler Bypass
Kit, Bypass rebuild, Sonnax 36605-02K, Amazon $20.60
-R&R Boost and P/S hosesHose, Hydroboost to pump, Gates 352800, Amazon $18.48
Hose, Hydroboost to steering box, Gates 352790, Amazon $5.68
-R&R rearview mirrorHose, Hydroboost to steering box, Gates 352790, Amazon $5.68
Mirror cam, dash cam, 1080P, 30fps, Auto-Vox V5Pro, Amazon $209.99
-R&R Headlight bulbsBulb, H13 LED, 70W, 6500K, fan cooled, pair, Beamtech S2-COB-H13, Amazon $31.75
November 21, 2022.....279,000 miles
Information starts at post #859
-R&R Torque Converter
Torque Converter, low stall, billet, PDQ custom, Installed by AA Design & Performance Tuning, $650.00 + labor.
March 18, 2023....281,000 miles
Information starts at post #872
-R&R Mud Flaps
Universal Mud Flaps, pair, Husky 17151, Amazon $65.68 x 2
-Install SubwooferPowered subwoofer, 10", 1000W, Rockville RWS10CA, Rockville $139.95
Installation kit, 8 GA, Rockville RWK81, Rockville $15.00
June 1, 2023....282,000 miles
Information starts at post #878
-R&R Water Pump Intake Elbow
Gasket, Motorcraft F81Z-8255-AA, Dieselorings.com $5.13
Hose, lower radiator, Gates 22434, FTE member
September 22, 2023....283,500 miles
Information starts at post #931
-R&R Front Shocks
Shock, front, 4600 Series, Bilstein 33028187, Amazon $84 x 2
Shock, rear, 4600 Series, Bilstein 33185347, Amazon $77.03 x 2
Shock, rear, 4600 Series, Bilstein 33185347, Amazon $77.03 x 2
December 15, 2023....285,000 miles
Information starts at post #962
-R&R Radio
Radio, 9", 1 DIN, refurb, Jensen CAR910X, Amazon $219.00
Harness, radio, Ford 98 and up, Metra 70-1771, Amazon $5.99
Adapter kit, American International FM-K550, Amazon $13.55
Holder,cell phone,dash/windshield mt, iOttie 5 2nd gen, Amazon $18.95
Cord magnets, Sinjimoru MCH_BASC, Amazon $11.19
Harness, radio, Ford 98 and up, Metra 70-1771, Amazon $5.99
Adapter kit, American International FM-K550, Amazon $13.55
Holder,cell phone,dash/windshield mt, iOttie 5 2nd gen, Amazon $18.95
Cord magnets, Sinjimoru MCH_BASC, Amazon $11.19
Last edited by BWST; 04-22-2021 at 09:24 AM.
#2
One of the issues this truck has is the passenger stub shaft is always turning with the wheel, even with the Warn manual hub unlocked. I noticed the vacuum nipple on that side was broken off, with the old vacuum hose hanging nearby. Looks like it's been that way for awhile, possibly allowing water/dirt to enter the inner bearing where the stub shaft rides.
Here is the snapped off vacuum port.
I capped it off with a brass plug.
What do you think it will take to free up the shaft from the hub? I can probably remove the hub and shaft assembly as a unit and work on this in the shop. Hoping the shaft is not too badly damaged from this. Assuming I need to separate the shaft from the hub assembly and clean it up, then replace the small bearing it rides on inside the hub assembly, if possible.
Here is the snapped off vacuum port.
I capped it off with a brass plug.
What do you think it will take to free up the shaft from the hub? I can probably remove the hub and shaft assembly as a unit and work on this in the shop. Hoping the shaft is not too badly damaged from this. Assuming I need to separate the shaft from the hub assembly and clean it up, then replace the small bearing it rides on inside the hub assembly, if possible.
#3
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#4
#5
Thanks for the welcome back, Sous!
#6
With a few light taps, I could see the axle move a bit, and locking the u-joints with a bar while trying to turn the hub showed a little movement. I gingerly pried and coaxed the hub assembly and axle shafts with their seals out as a unit, then with more penetrating oil and some back and forth tapping, separated the hub from the stub shaft. Some water definitely got in there.
This side of the front axle is a beast. I never pulled axle shafts before. They are substantial.
Predictably, the needle bearings are shot. The shaft is pretty scored up as well.
So I need a stub shaft, a u-joint, some seals, and a needle bearing. Kinda fun learning about all this. Might pull the other side too and see where things are at. I think the bearings are ok there, just some dust seal wear, though the needle bearings might be low on lubrication. Good time to check the brakes on that side as well. It pulls a bit to the left.
Edit: adding reference to SuperdutyPSD.com's ball joint R&R article - has excellent instructions for removing the unit bearings: https://www.superdutypsd.com/ball_joint_article.php
This side of the front axle is a beast. I never pulled axle shafts before. They are substantial.
Predictably, the needle bearings are shot. The shaft is pretty scored up as well.
So I need a stub shaft, a u-joint, some seals, and a needle bearing. Kinda fun learning about all this. Might pull the other side too and see where things are at. I think the bearings are ok there, just some dust seal wear, though the needle bearings might be low on lubrication. Good time to check the brakes on that side as well. It pulls a bit to the left.
Edit: adding reference to SuperdutyPSD.com's ball joint R&R article - has excellent instructions for removing the unit bearings: https://www.superdutypsd.com/ball_joint_article.php
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#7
Looking good so far.
Do you have or have access to the large vacuum seal tool? If not I have the Lisle tool you can borrow.
The Timken Needle bearings are pretty inexpensive too. https://smile.amazon.com/dp/B000BZ54...v_ov_lig_dp_it
Do you have or have access to the large vacuum seal tool? If not I have the Lisle tool you can borrow.
The Timken Needle bearings are pretty inexpensive too. https://smile.amazon.com/dp/B000BZ54...v_ov_lig_dp_it
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#8
Looking good so far.
Do you have or have access to the large vacuum seal tool? If not I have the Lisle tool you can borrow.
The Timken Needle bearings are pretty inexpensive too. https://smile.amazon.com/dp/B000BZ54...v_ov_lig_dp_it
Do you have or have access to the large vacuum seal tool? If not I have the Lisle tool you can borrow.
The Timken Needle bearings are pretty inexpensive too. https://smile.amazon.com/dp/B000BZ54...v_ov_lig_dp_it
#9
Some more pics of the rig:
As you can see, the stock air box is there. I suspect it has not been sealing well at times. No blowby at the oil fill, but the stock garrett turbo has evidence of dusting:
Interior view. The driver seat leather has been replaced. Passenger side is pretty worn, but not ripped.
Transmission dipstick tube was broken off and lodged down on the passenger framerail. There's a plug sitting in the remaining stub. Not a good sign, but it drives/shifts well (so far).
The downpipe appears to be the stock diameter (3"). 3.5" stock exhaust starts after the pipe transitions to horizontal.
As you can see, the stock air box is there. I suspect it has not been sealing well at times. No blowby at the oil fill, but the stock garrett turbo has evidence of dusting:
Interior view. The driver seat leather has been replaced. Passenger side is pretty worn, but not ripped.
Transmission dipstick tube was broken off and lodged down on the passenger framerail. There's a plug sitting in the remaining stub. Not a good sign, but it drives/shifts well (so far).
The downpipe appears to be the stock diameter (3"). 3.5" stock exhaust starts after the pipe transitions to horizontal.
#10
Working through another issue in parallel. The transfer case will not shift from 2WD to 4Hi or 4Lo. Forscan lite on my S7 phone shows code P1820. No Low Range light when ignition key is turned. I do have the 4x4 light.
Good [link] to what @Baatzy worked through. I think my issues are likely wiring/connector related.
I'm referencing the ESOF troubleshooting guides for a 2000 truck from our tech folder as well - very helpful
What I've checked so far:
- all fuses in the central junction box and under hood junction box. removed and reinserted as well.
- no power to shift motor when I operate the selector switch. no clicking from the under hood shift relays either.
- shift motor - works when I apply 12V. Operates one direction or the other depending on the polarity I apply.
- selector switch - forscan shows GEM is seeing it switch between 2WD, 4Hi, 4Lo. Measured voltage on dark blue wire at switch in each position: 5.6V, 2.5V, 0.9V
- dash indicators - just have 4x4, not Low Range. Checked by removing shift encoder from shift motor assembly and moving it manually. Might have a bad light.
-shift relays - bench tested - appear to work with power applied, continuity verified between appropriate blades of the relay energized and de-energized.
-power at shift relay mounts, location 86 and 87, both relays. Grounds appear good at 87a, both relays.
-pulled fuse block/GEM and it appears to be in good shape in terms of no water damage. Solder joints look good both sides of PCA. All connector pins clean.
I can apply power to the shift motor by jumper at one relay mount, 30 to 87, leaving the other relay to provide a ground path. Shift motor runs when I do that.
Connector to the shift encoder will not latch - easy to slide off. When sliding it on, it does not click, and I can't slide the red clip in. I think the nub on the encoder side is worn, Not sure yet best way to fix this.
I appear to have an open wire between low-to-high shift relay coil pin 85 and GEM C240c pin 10, ckt 782. I have continuity between the other shift relay coil pin 85 and GEM C240c pin 11, ckt 781.
Note in the illustration, the view of the relay mount is from underneath (what they call "harness side").
Good [link] to what @Baatzy worked through. I think my issues are likely wiring/connector related.
I'm referencing the ESOF troubleshooting guides for a 2000 truck from our tech folder as well - very helpful
What I've checked so far:
- all fuses in the central junction box and under hood junction box. removed and reinserted as well.
- no power to shift motor when I operate the selector switch. no clicking from the under hood shift relays either.
- shift motor - works when I apply 12V. Operates one direction or the other depending on the polarity I apply.
- selector switch - forscan shows GEM is seeing it switch between 2WD, 4Hi, 4Lo. Measured voltage on dark blue wire at switch in each position: 5.6V, 2.5V, 0.9V
- dash indicators - just have 4x4, not Low Range. Checked by removing shift encoder from shift motor assembly and moving it manually. Might have a bad light.
-shift relays - bench tested - appear to work with power applied, continuity verified between appropriate blades of the relay energized and de-energized.
-power at shift relay mounts, location 86 and 87, both relays. Grounds appear good at 87a, both relays.
-pulled fuse block/GEM and it appears to be in good shape in terms of no water damage. Solder joints look good both sides of PCA. All connector pins clean.
I can apply power to the shift motor by jumper at one relay mount, 30 to 87, leaving the other relay to provide a ground path. Shift motor runs when I do that.
Connector to the shift encoder will not latch - easy to slide off. When sliding it on, it does not click, and I can't slide the red clip in. I think the nub on the encoder side is worn, Not sure yet best way to fix this.
I appear to have an open wire between low-to-high shift relay coil pin 85 and GEM C240c pin 10, ckt 782. I have continuity between the other shift relay coil pin 85 and GEM C240c pin 11, ckt 781.
Note in the illustration, the view of the relay mount is from underneath (what they call "harness side").
#11
#12
Finding that break is going to be a challenge. Looking at the exposed wires under the dash from the relevant connector, and under the hood from the relay mount to the firewall - no obvious spot. I thought I'd start with cleaning up these fender mounted connectors.
Here's the shift motor encoder connector. Interesting how the red slide works. I'm trying to understand it, but it appears to be locked open when not inserted in a connector. I think the nub in the mating connector has to push the tip of the red slide such that the whole red clip can slide home. I played with the connector on the MAP sensor which operates similarly. Still hard to see what's going on there.
Here's the shift motor encoder connector. Interesting how the red slide works. I'm trying to understand it, but it appears to be locked open when not inserted in a connector. I think the nub in the mating connector has to push the tip of the red slide such that the whole red clip can slide home. I played with the connector on the MAP sensor which operates similarly. Still hard to see what's going on there.
#13
This guy had the same issue with the open ckt 782:
https://www.superdutydiesel.com/thre...g-p1820.24445/
If cleaning and reseating the fender connectors does not solve the problem, I might run a new wire. There are some extra wires labeled "customer access circuits" that pass through the firewall. I could use one of those.
Several weatherproof joints to make though to get that BR/WH wire connected. Certainly better if i could find the break.
https://www.superdutydiesel.com/thre...g-p1820.24445/
If cleaning and reseating the fender connectors does not solve the problem, I might run a new wire. There are some extra wires labeled "customer access circuits" that pass through the firewall. I could use one of those.
Several weatherproof joints to make though to get that BR/WH wire connected. Certainly better if i could find the break.
#14
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