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I was looking at an exhaust leak under my hood yesterday when I noticed the casting #'s on the block. My truck is a '77 and the valve cover matches that. The casting # starts with D5xxxxx, so is it common to have a '75 engine in a '77 and still be original? Two years difference seem like a long time .
Also my emission sticker reads that "this vehicle conforms to 1977 gas fueled HD truck engines." This doesn't mean I have the HD version of the 300 L6, does it?
This is very common. The 300 was used for several years with the same castings. So the casting mold was made in '75 but the part could've been cast later.
According to federal emissions, the light duty trucks (under certain gvw) needed emission equipment. Ford started making the F150 (heavy duty half ton) to be over the gvw limit and thus not need emission equipment. So your 300 is probably a standard non-emissions '77 pickup engine.
the early years like that were emissions exempt on the "heavy" duty trucks, being anything over 1/2 ton. It wasn't until into the 80's that all light duty trucks got hit with emissions control.
The D5TE number is a Design code .
This means that part was desginged in 1975 but could still be cast & intalled in later vehilces with slight change-ups
ie: Intake manifold
D5TE-9425-A
vs
D5TE-9425-AB-A
There should be a suffix code at the very end of the numbers you are looking at.
The D5TE-9425-A is the very first design in 1975.
An intake manifold used in a 1976 could very well have 2 change-up suffix Letters like 9425-C (from A to a C)
Had the change-ups never occur, you could have a D5TE-9425-A cast in 1977.
Look at the actual Date Cast numbers.
Most engine & drive train parts are cast 2 months before use.
Here's my guess;
I say you have a D5TE- 6015-B block,a D5TE-9425-E intake cast 2-3 months before it was built.