So what are the differences between the early 1999 PS and the 99.5 PS engines?

What do I need to do to mod my early PSD up to latter specs?

Thanks!

 

Engine wise, the only difference is the intake assembly and injectors. A number of us with E99's have made the upgrade to "not so early" '99's. Changing injectors isn't a big deals, most upgrade to single shots anyway.

There's a few shops with the kit, Clay has it the cheapest. Only reason to do all that is if you're looking to go big power and need a bigger turbo like a 38R, or bigger.

Riffraff Diesel: Early/Late Conversion Kit

There is an aftermarket turbo, D66, from Bean's that is a direct bolt on to the E99 pedestal.

Beans Diesel Performance - Early 1999 Power Stroke BDP Dominator 66 Turbo (Powered by CubeCart)

 

Quite a few differences. Here's a few:
- Early 99's have smaller injectors (120cc AB's vs 140cc AD's in the 99.5+)
- Early 99's have a smaller HPOP (15 degree vs the 17 degree in the 99.5+)
- Different air filter box
- Different intake spyder
- Early 99's have smaller intake plenums (2.5" vs 3" in the 99.5+)
- Early 99's do not have an intake air heater
- Early 99's have a slightly different turbo with a smaller compressor outlet than 99.5+
- Different turbo pedestals

And there are some other differences as well that aren't engine related (such as brakes, wheel hubs, etc).

 

Pocket

Thanks for the list. Nothing I want to tackle right now. The beast really does seem to run good.

I love it.

It also gets good fuel mileage. I plan to drive a lot of miles so I want to hang onto that.

Thanks again.

 

I'm pretty sure I have a 99.25 PS. Early suspension and brakes but late motor. Mine was built 02/99

 

I like the RR package to convert early 99 PSD to latter PSD.

He includes a pedestal with EBPV. I see that removal of the EBPV is considered desireable.

Think it is worth while to remove it and the butterfly while it is on the bench?

 

Yes. They tend to leak oil, usually the biggest reason people delete them. I live in cold weather and haven't missed it yet.

Downshift76- when was your truck built? I can't say I heard of one with an E99 motor and later chassis. Did someone do an engine swap?

 

The build date on the door is 03/98

At least that is what I remember. I will check again when I get home on Friday.

 

I have heard of some having early suspension and late engines with build dates between 12/98 and 3/99....I cant find the thread though.

 

When I get home I will check the s/n on the engine. See when it was built.

 

Downshift76- when was your truck built? I can't say I heard of one with an E99 motor and later chassis. Did someone do an engine swap?[/quote]


No I have Late Motor and Early suspension. It's really only affects me when I buy suspension stuff like lift. Build date is 02/99.

 

Thats why I call it a '99.25, it's not quite a early and not quite a late model

 

Some differences between Early 99 and 99.5

Credit to Chase aka superduty4x4, Ron aka Ron's Power Stroke and in Bold credit to Jet aka SolidGround

Early 99 has a wicked wheel in it from the factory. And much smaller turbo (spools faster, though)

The early99 has 120cc(AB code) injectors and the late99-03 has 140cc(AD code) injectors.

The early99 has 2" intake plenums. The late99-03 has 3" intake plenums.

The early99 has a 15* swash plate HPOP. The late99-03 has a 17* swash plate HPOP.

The early99 has one glow plug relay. The late99-03 has one glow plug relay and one air intake heater relay side by side (along with early '99 CA models) . Both relays are on the passenger side of the fuel bowl toward the front of the truck.

The early99 has a totally different air intake that is not inter changeable with the late99-03 (except for DRW trucks) . But you can put the late99 air cleaner assembly in the early99 truck. The only three afterarket air filters that work on the early99 are the AFE stage 2, the AIS and the KWIKK 6637.

The early99 track rod has smaller mounting bolts than the late99-03. (except for DRW trucks)

The early99 has shallower rotors than the late99-03. (except DRW trucks)

The early99 has shorter hub-bearings than the late99-03. (except DRW trucks)

The early99 front axle U bolts are square where they go over the spring pack. The late99 U bolts are round. (except DRW trucks)

The early99 has a different pitman arm than the late99-03. (except DRW trucks)

The early99 does not have the AIH like the late99-03. (except CA model)

The early99 does not have the automatic transmission fluid cooler in the radiator.

The early99 has no indicator light showing that "cruise" is on. Late99-03 has a cruise light that will come on when you set the cruise control. The early99 has the light in the dash already. A newer PCM(Yes it will plug in and will run better too) must be used to make the cruise light illuminate. It is a green light on the right side edge, half way up.

 

Some great and interesting info!

My Father has a 94.5 turbo 7.3, was only built for the half year just so ford could hurry up and get the turbo diesel on the market. What a headache to get parts for! Truck has over 375K miles on it now and every part we ordered from the ford dealership had to be sent back and reordered at least twice. I will make sure to never buy a half year oddball truck like that in my lifetime!