This weekend I finally got time to do the big stack of FTE-recommended mods that I'd been building-up for the last few months (and install all the new parts stored in the basement from brown-truck deliveries!).

...I can sum it up with WOW!!! (and ouch...for the uncomfortable contorsions you have to do to get some of this stuff in...but that is why we are enthusiasts!!)

Started out with my basicly stock 135K '99 7.3 CC 4x 6sp...no problems with it but noticeably less power after I bought the wife a 6.0L (I know it'll last though ). Did it all in my carport, temps 18F-35F (I love Carhart!), no help (wife knows better than to be around when something goes wrong) and I've never tinkered with a diesel before other than regular maintenance.

<>1st - ZooDad Mod - super-EZ 10 minutes -- my only complaint I wish could use my hole saw more!
<>2nd - out with the old stock air box, in with the AIS -- perfect fit & finish and big air!
<>3rd - CCV Mod - I wasn't planning on doing it until I tore the turbo apart for the wicked wheel and had to spend an hour and almost a bottle of carb cleaner getting the 1/8" of oil gook-sludge out of the turbo passages << obvious source (and trail of oil) the CCV in the intake. Trip to the store and all is good now. $25 and also super-EZ. Thankx to my local Exhaust Pros for the freebie 4" to delete the CCV in the intake! Smell isn't that bad...
<>4th - Whicked Wheel - I did this mod on-engine and it went super EZ (especially after I'd already disassembled everything else for other mods), worst part was the oil-gook from the CCV. Old wheel was pretty well blasted though...I can only imagine what it looks like downstream from it (it had 135K w/K&N...never again). I'll try to post pics in my gallery later of how the K&N modded my old turbo blades. Boy does the Wicked sing though!!
<>5th - SS HPX Line - Super-EZ also and even easier if you're doing the wicked wheel at the same time. I think the engine is quieter but its hard to tell when I'm only listening for turbo!
<>6th - MAP Line Regulator - Again super-EZ and no SES lights yet!
<>7th - Mark R. 5" Exhaust w/muffler - Good instructions, did it without jacks. Went pretty much as planned...definitely take your time aligning as it is very tight at rear shock/spare tire. Hint: Move all pipes as far forward as you can to have the pipe drop down right after the axle for best clearance...just make sure your axle won't hit in full travel. Hint #2: A milk-crate and some phone books under and around the down pipe at the bottom will hold it securely until you can get the V-clamp on. Hint #3: Delete the washers from the kit on the hangars...you don't need them and they jingle-rattle like crazy. Hint #4: When retracting the spare tire hold toward the drivers side and it will secure and give you more room for pipe. Hint #5: Go off-road right after install...you'll find every place that it'll rub immediately. I got the 6" SS tip but haven't installed yet...I'll definitely need to upgrade the looks of the rest of the truck before I put that much bling on! Lastly, great sound (kind of a mix between an IH 1466 Turbo Tractor and a NAVSTAR school bus), no drone in the cab, may be a bit quieter in cab at speed, as quiet as stock when idling through neighborhood...all choppy turbo-whistle on top of V-8 grunt after that!
<>8th - DP 6-flip Chip - Great company, great people, great product, great instructions!...and WOW!...it has been a long time since I've had to watch for police!
<>9th - Dual gauge A-Pillar ISSPRO setup from DieselManor - VERY elaborate instructions, EZ install (esp. w/ up-pipe clamp-on EGT probe), time-consuming...but perfection is worth it!

Now for the casualties: one well-scuffed pair of Carhart coveralls, one completely trashed brand new pair of Mechanix gloves, 12-pack and 2 pizzas, 3 drop light bulbs (don't call 'em DROP lights for nothing) and I found the plastic "Powertroke 7.3L" cover above the fuel filter is not a good place to lean on if you start to lose your balance.

Other goods: Good time to discover that thermostat seal is leaking and change it with everything out of the way. Also good time to realize that all of the hoses & harnesses that lay across the passenger side intercooler tube are chaffing it badly...wrapped tube, hoses and harnesses with inner-tube rubber to stop chaffing before it chafes through. Will inspect inner-tube to see if holds up to temps in a couple weeks...so far, so good.

Still on my to-do: Pre-pump mod - I have all the parts but was too darn cold, tired and sore to tackle that job.

Thanks FTE!!! ... definitely going to the "Supporter" site now!

 

Man, that just makes a fella feel good!

 

That is great! A wonderful inspiration. I have a day like that coming up after Tax Day in April. Not so many things, but still, it will be a fun weekend.

 

Lester,

They make some metallic tape (with REAL good stickum' on it) for use in the HVAC industry. Layers of this tape, added to just the right spots on your intercooler pipe, is just the right "ticket" to prevent further erosion of that pipe.

Pop

 

Wow, what a weekend! Nice going on all those mods.

 

Well it sounds like you made a major attempt at curing your PMS, but I'm sure it will come back even stonger than before now!

 

wow, it must have felt nice to do all that PMSing in two days!

 

Thanks all,

Yes I think I'm temporarily cured of PMS...now I can't keep myself out of the truck or my foot out of the pedal. I'll probably need a booster shot for PMS in the near future though.

Attached is the pic of my stock wheel with 135K of wear & tear (looks bad to me)...remember that was 135K with a K&N in the stock box...enough said

Second attachment is why I decided to do the CCV mod at the last minute...inside the turbo was worse because it had been centrifugally plastered and cooked to the sides. As far as I could see down the intercooler pipe looked that way too. ...something else on the to-do list.

 

Booo that makes me shudder. Good thing you got that all cleaned out and fixed up!

 

Wow, I'm tired now just thinking about all the stuff you did. Nice job getting it all done, increase the fun factor for sure.

 

Good work. That turbo wheel makes me want to run outside and tighten down my intake clamps some more. You reckon it was the K&N or an intake leak?

 

Wow, that wheel looks like the blades on my mower.

Great job. Definitely a motivator for the rest of us. Congratulations!

You hit the nail on the head with the NAVSTAR school bus. I've been racking my brain trying to figure out what the 5" sounds like.

 

Nice work, and a busy, but very satisfying weekend!!

That turbo wheel was really chewed up. Good thing you replaced it.

When I took my turbo apart, it was plastered with oil too. I've got some pictues in my gallery of what the stock one looked like. But, my intake pipe didn't look nearly as dirty as yours. I can only imagine what the inside of your turbo looked like.

Well, it's only a fun downhill slide from here. After the pre-pump mods will come the regulated fuel system, transmission upgrades, dual HPOP, injectors, a bigger turbo, new intercooler, etc.... Welcome!!

 

Smoke that 6.0 now though eh? Wow, that must of been a great and exciting weekend.

 

Man, all I can say is YOU DA MAN. Makes me fill bad about putting off some of the routine stuff I need to do. It has taking me 2 years to do half that much. Congratulations on your job well done. I know how good it feels just to do one mod at a time. I don't know if I could handle the excitement of having it all work at once. GREAT JOB