Well, the Phoenix has risen with a new heart. My truck has its, new to it, engine installed and running great. Here is a rundown of the issues that precipitated this transplant. I had an EGR cooler failure only 2 weeks after buying the truck. I decided to do a First Coast Diesel EGR delete system. I did not replace the oil cooler, only back flushed it. This turned out to be a very bad decision. The truck ran great for 18000 miles. In fact I was ecstatic about how strong it was running. Then the catastrophic oil cooler failure happened. After replacing the oil cooler, installing new head gaskets, MBRP exhaust and an SCT tuner I went through a period of 3 different cylinders bending push rods. Four new hydraulic lifters and it finally ran for a while. In fact it ran fantastic with the SCT tunes and the new exhaust. Then 850 miles later, 400 miles from home, it just quit. I had made a decision earlier that I would not be able to trust this engine if it quit again. I decided to look for a replacement. I looked for 2 months for the right opportunity. I stumbled into a great deal. While talking to a local auto parts recycler about a 6.0 engine he had listed on Car-parts.com, he told me he had 2 engines but one was out of a van. I went to look at the pickup engine. He had them both sitting on the floor when I got there. They were both 2006 FMC test vehicle engines from a prototype shop. The pickup engine had test sensors and harnesses still on it. The van engine was new!!! The van was used for body panel fitment issues and the engine had only delivery miles. I could have my choice of engines for $2400. The van engine had no computer, turbo or engine wiring harness but it was new. I could see several interchangeability issues but bought the van engine. I am so glad I did. It turned out to be not as big a deal as it first looked.
The differences that mattered ran from the obvious to the subtle. The largest issues are all related to the oil filtering system. The van has a remote oil filter assembly which is bolted to the upper oil pan and hangs off the driver’s side of the engine. The entire oil filter system had to be swapped with my original engine parts. This included the lower oil pan, upper oil pan, dipstick and the tube, oil/fuel filter housing and mounting base. Both valve covers are different so I used the originals. The fuel lines to the heads are different so again I used my originals. The EBP tube is different as well. The FICM mounts on the van body so I needed the brackets off the original. The glow plug module mounts on the opposite valve cover on the van engine, more original part swapping.
There is some good news. The front cover with its oil pump and water pump is exactly the same as the 04 pickups. The rear cover and flex plate are the same. Exhaust manifolds and turbo y pipes are the same. My turbo bolted right up to the 06 pedestal. After a close inspection and complete re-taping, I used my entire electrical harness and FICM. Everything fit and worked. As I prepared to install the new engine I installed all the reliability modifications I could find. I installed the ARP head studs, my FCD EGR delete kit, installed the 05 and up HPOP STC fitting kit, Edge Insight EGT probe and Dieselsite coolant filter. I am installing an ISSPRO fuel pressure and oil pressure gauge. I installed an Edge Insight monitor to watch the rest of the engine vitals. A new serpentine belt, pulleys and tensioner were installed.
We pulled the engine out the front of the truck. Obviously this required removing the entire front of the truck. It was not that bad. Just unbolt and unclip everything as you move from the bumper to the engine fan. It was kind of like eating an elephant, just one bite at a time. We used a 2 ton overhead chain fall to pull the engine and transmission out together. Darn, that was some heavy lifting. We had to remove the oil pan and oil pickup tube to clear the front cross member. After completing all the engine part swapping and the upgrades we ate the other half of the elephant. We just re-installed everything in reverse order, one part at a time. We changed all the filters and fluids on the truck and put in 2 new batteries. It fired right up after about 15 seconds of cranking. I have about 200 miles on it and it runs great. I am pleased to say the least.
I have to say that I could not have done this without the tremendous support I received from this site. There are many to thank here. Bismic, Cheezit, CJ, Matty and Tex25… were very giving of their time and knowledge. I am grateful. To the others that I have missed, thanks to you as well. I must also thank my nephew Brian for all his help. He did most of the work and all the heavy lifting. I know this is a long post but I thought that my experience may help others with similar situations

Regards

 

What an accomplishment - congratulations! You got a good deal with that engine for sure. Sounds like you took your time and did all the right things. You should be getting YEARS of reliable performance as the reward for all your hard work. There are few things more satisfying than successfully tackling a big job like this.

 

Mark,

Thanks, I meant what I said earlier about you and the others that help out here. I hope others with similar issues are helped out by my info.

Regards

 

good job keep up the good work

 

Thanks, It has about 3000 miles on it since it rose up from the ashes. Truck is running better than ever and better every day. So far there are no problems or leaks. Mileage started out at 15.2 and at today's fill up it was 17.8. I learned a ton about these trucks and their high powered hearts in this endeavor.

 

damn man! Thats b'dass!!! Im glad everything worked out for you!!! Im hoping my issues are minimal

 

Good Deal on the motor. Great that it is running good, It feels good when all that hard work pays off.

 

excelent very glad it all worked well for you. enjoy it.

 

Glad everything went well for you and this should help the next guy who faces this question of will it work. The basic engine is the same, just a few minor issues that you can cross over to another vehicle year. Johnny Cash wrote a song called One piece at a time....

 

One piece at a time... That very well sums up how you have to attack that job. I liken it to the question, How do you eat an elephant...One bite at a time. I will not say that my nephew would agree but I learned so much while doing the job I would not hesitate to take on another one. Just do not want it to be mine. Before I started the project I pondered out loud on this site about the van to pickup differences. Cheezit jumped in with some great advice. He just said take your time and make the new one look just like the old one and put it back in. He was right.

Thanks to all