As promised I have my truck all done with phase one and I will give you all a breakdown of what was done. Keep in mind most of what I have done was from picking up knowledge from you guys and this site! I want to say THANK YOU for all the help and patience you all have shown this newbie! I think I am getting a good hold on this truck and what she needs.

1) I ordered an SCT X-3 with custom tunes from Eric at Innovative. I had a few problem at first but with some tech support and Eric’s help they are in the past and this thing seems to work good.

2) I had my EGR cooler welded shut and checked for leaks. Installed welded cooler back in truck.

3) Had a block off plate made local from aircraft aluminum to delete the EGR valve. Worked out great!

4) Took intake off and power washed….. This thing was DIRTY! I can see now why this causes so many issues. The engine has to try and bring that crap back in and burn it…. Now I know why the oil gets so dirty and causes oil cooler issues.

5) Installed new oil cooler core. Again, this thing was DIRTY! I would guess I dropped a few degrees in oil temp with this addition.

6) Replaced the STC fitting on the back of the HPOP with updated fitting. The old one was just hanging there and ready to GO pow.

7) While we had this all apart we found the turbo sticking and hanging up due to rust on the VGT side. We took all apart and bead blasted to a good clean surface. (seems to be working better now)

8) Full coolant flush and added lubricant for water pump.

9) Installed 4” MBRP 409 stainless steal turbo back exhaust. That sucker (blower) sounds sweet!

And finally once the truck was back on its feet we checked fuel pressure….. It was at 50psi when idling. Put the truck in gear and stood on both pedals and pressure dropped to 45-43psi. I will be installing a new fuel pump and set of filters tonight. 45psi is the minimum allowance for the injectors to function properly and I would probably be ok but I have come this far and thought I just as well do it now.

Over all this was a fun project! I had a few trials with the tuner at first. I somehow was loaded with programs from an 03-04 6.0 and the computers in the 05 and up are different. SCT was able to remote connect to my PC while I was connected to the device and get it straightened out. After that the tunes loaded just like they were supposed to and life is good. I am currently running the STREET file the Eric made for me. I can tell you I reverted to high school last night and put down a few markers on the road! She lit up the tires through 4 gears before I backed off!!!!!

The Exhaust kit was a piece of cake! All the hangers and brackets worked just like advertised. It is a little bit louder than I was looking for but I think it will be ok.

Again, thanks to all for helping me get to this point! I did snap a few pics to post but cannot seem to get them off my d@m Black Berry….. Phase two is going to be gauges and APR studs and, and, and, and…… ;o)

JT.

 

Congrats!!

 

Thanks man! I am a little excited about it if you cannot tell. I have a BSEG today!

 

Congrat's! Be careful with the fun pedal untill you get your gauges. EGT's can climb like crazy!!

Please clue me in on the updated STC fitting on the HPOP. What is the fitting and when did Ford come out with an updated one?

 

You may want to shim your fuel regulator, a new pump won't raise the idle pressure from 50 since your regulator spring is weak. I was getting 53 idle and dropping to 45 at WOT. Did the BB mod (put a BB between the spring and brass cup) and it upped idle pressure to about 62 and WOT drops to 55 minimum now.

 

The updated filling is a solid threaded connection. The "old" fitting is a snap ring typ connection. Im sorry I do not have a part number and the package is long gone. I think Bismic has it though!

 

I will check that out Cartmanea! Thanks!!

 

Is that in the tech folder, I have 60k on mine and its probably time to shim the spring here too.

Sarge

 

I've never seen a guide to it on this forum, but I've seen it on The Diesel Garage and I think on Powerstroke Nation.

 

Go to a bobcat dealer. Ask for part #6592105. It's a steel BB that's perfect for shimming the fuel regulator. cost about 10 cents. carefully remove the fuel return line from the secondary fuel filter housing and the 4 small torx head screws that hold it on. DON"T drop the little parts inside. Put the BB between the spring and the plunger and reinstall. FWIW--I hope you all know that by raising the fuel pressure you are actually getting LESS fuel volume from your pump. If you don't know for sure that you are having a fuel pressure problem then leave it alone. You probably only need to do this mod IF you are running a tuner with some fairly hot tunes. A fuel pressure gauge is the only sure way to know.

 

Definitely don't do it without a fuel pressure gauge. I used a regular copper BB, cost about 1 cent, I had a carton of 500 on hand.

 

Yeah thats next on my list of things to do as well as a coolant temp guage, then an oil temp guage. The list is long but I am chippin away at it.

Sarge

 

HAHA......the list is never ending. Always something to do or tweak.

 

Ok guys,
I have a problem that came up in the last day or two. I have been hearing a loud air sound under the hood since I put this thing all back together. I have also noticed a little reduction in boost.... Last night I was crawling under the hood and think it is on the pressure side of the turbo. I am going to soap it up and see if I can tell for sure where it is at but thought I would see if anyone has some trouble shooting ideas that may help. I think it is coming from right around the turbo area.... Is there a seal on the pressure side of the turbo?
I had the exhaust side appart to clean it but never the pressure side..... Dam.... It looks like that sucker may be coming off again.

 

I THINK I found the problem. I installed a block-off plate where the EGR valve used to be and it was loose.... I know it was tight when I put it back together..... I may need to try a diff gasket and possibly longer bolts.

I will keep you posted if I do indeed need to look into the turbo a bit more.