Project Shamu Build - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 1111 (permalink) Old 07-11-2017, 04:16 AM Thread Starter
Project Shamu
 
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Project Shamu Build

Hey Nation, I've owned my truck for 3 years now, and I wanted to put together a little thread that tells this old 96's story...

It started out life as a truck owned by a company called Bens Asphalt, a 96 CCLB 2wd with a 7.3. Ben's owned the truck for 280,000 miles, never modified anything, down to the stock downpipe and air filter housing. They sold it to a dealer in southern california, where the previous owner purchased it.

The previous owner owned it for another 40,000 miles, and installed a K&N intake that he had won at a raffle, removed the exhaust at the downpipe so that it would sound loud, and put on some Method 18" wheels. Still basically stock, unmolested at 320,000 miles.

Then i bought it in August of 2014. (and it was all downhill from there.. haha)
What she looked like when i bought it:


It leaked like hell, oil from the dipstick tube, oil leak from the turbo, HPOP was leaking, MASSIVE fuel leak(s) from the fuel bowl, fuel pump, etc. Up-pipes leaked, transmission leaked, powersteering leaked. The list goes on, and I had a lot of work to do!

Pic of under the hood after some extensive cleaning.


Now it being owned by an asphalt company, the interior was hammered, so the previous owned replaced the headliner, and had all the seats reupholstered. The carpet was still in decent shape so it was original.

The motor, despite leaking from every orifice it seemed, still seemed very strong. Had little blowby, never had a problem with cold start, and was only about 2 quarts low between oil changes.

And so, the story begins. I'll be adding more and more to this thread, as I try and recall what I did over the last 3 years, going through my old pictures and old threads. Keep in touch guys!
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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
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post #2 of 1111 (permalink) Old 07-11-2017, 04:27 AM
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Re: Project Shamu Build

Subbed! Can't wait to see more of this story revealed! If I may jump ahead, you did replace the K&N right?

Shoulda bought a Cummins.

1997 F250 7.3L XLT, 4x4, 5spd, 315K, TS chip, BD Turbo-Thruster II, Donaldson 6637 filter, 4" straight piped dual exit SOLD

1995 F350 CCLB 5.8L XLT Tan leather interior. Soon to be swapped onto a 6.0 frame.


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post #3 of 1111 (permalink) Old 07-12-2017, 02:13 AM Thread Starter
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Re: Project Shamu Build

Long story short, No, I still have it.


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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
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post #4 of 1111 (permalink) Old 07-12-2017, 02:55 AM Thread Starter
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Re: Project Shamu Build

So the first "mod" that I did was in April of 2015, almost within 8 months of getting it. And it wasn't exactly a mod per say.

I had to put a transmission in the truck! Mine was shifting very rough, and slamming into gear going into 3rd and 4th. So just for the time being, I purchased a trans from a friend of a friend that was parting out his 96 F250. Supposedly "rebuilt" with about 5,000 miles ago, and had some "upgraded parts". Yeah BS. After I bought it for $600, I pulled the pan, fluid was pretty dark, magnet was covered in clutch material, pan had a dent in it. I guess for $600 I couldn't complain, So i pressure washed it real good, cleaned out the pan, the magnet, and went to go install it at the shop.

Now, at the same time, I was aware of my exhaust leaks from the stock up pipes having so many miles on them, so I purchased RiffRaffs Bellowed Up-pipes to install at the same time. Did it all across 2 nights after work, it was a bear to lift that transmission up with just a floor jack and a 4x4 by myself!!!

New trans, all cleaned up, with the TC that came with it, harness and all.



And a comparison of the old transmission to the new (the old one has seen better days for sure).
I still have this transmission sitting in my garage, I cleaned it up with the pressure washer a few months ago and found a Ford "Remanufactured" sticker on it too. Definitely not original, who knows how many miles.


Sorry no pics of the up-pipes, but it was a bear to install, until I removed the turbo outlet and slid the down pipe out of the way. (Which looking back now, I should've installed a 3" Down Pipe at the same time!!!)
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File Type: jpg CAM00200.jpg (19.5 KB, 450 views)


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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
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post #5 of 1111 (permalink) Old 07-12-2017, 02:59 AM Thread Starter
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Re: Project Shamu Build

Then i got my steering wheel! My wife bought me it for my birthday, a Grant Deep Dish wheel, and I just so happened to have a hex shaped quick release sitting in a box at the shop, so on she went!




The smaller steering wheel is sooo much nicer to drive with, and at the time, my cruise control wasnt working anyways, so I just ripped the buttons out of the wheel and tossed it.

Not to mention being able to remove the wheel whenever i go in somewhere, or park it for long periods of time, I just remove the wheel and take it with me.
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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
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post #6 of 1111 (permalink) Old 07-12-2017, 03:37 AM Thread Starter
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Re: Project Shamu Build

My next mod was to find my fuel leak!!! May 2015, 9 months after buying the truck, I finally had to fix it, it had gotten so bad to where my driveway was beyond saving!



So I first looked online and found some of the main things that leaked, the drain valve, and all the rubber hoses, so i hit up dieselorings.com and ordered them all. replaced them all and tried it again. No difference.

So i figured the best way to find where the leak was coming from (as i didnt know at the time), was to get the fuel bowl out of the valley so I could eliminate that as a problem. In comes the Fuel bowl delete (my version atleast).

I took the tightwad mod, and modified it a little for ease of install. The original thread was very vague, so I had to kind of figure it out as i went along. And to not risk breaking something and being screwed, I bought a spare fuel bowl with the FPR. Heres the install: Easy Fuel Bowl Delete w/ Pics

Getting the filter out of the valley allowed me to verify if it was a cracked fuel bowl, or something else. In this case I found it was the weep hole on the pump leaking, I could actually see it with a small mirror. So onto E-fuel I went.

My E-fuel Build Is how I did my e-fuel conversion, Mark Fuga got ahold of me on this forum and told me about his fuel kit, minus the pump and filters. And i jumped on it. Its a fantastic kit that I still love to this day. If you need to get ahold of him for one, he has several options from pieces of his kit, to a full kit that includes everything down to the wiring.

Fuel leak fixed! Woohoo!!!
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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
SOLD
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post #7 of 1111 (permalink) Old 07-12-2017, 03:38 AM
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Re: Project Shamu Build

interested....
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post #8 of 1111 (permalink) Old 07-12-2017, 03:50 AM Thread Starter
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Re: Project Shamu Build

Next after that was the Big 3! Gauges, Down-Pipe and Tuner!

I went with glowshift gauges, as I'm a cheap ass, Diamond Eye 3" DP, and PHP Hydra Tuner with Swamps custom tunes.

The downpipe sucked, with sagging body mounts it was a pain, but after a few hours I got it in. It rubbed a lot at first, and took me a while to get it in the perfect spot.


I also installed RiffRaff intake boots, as mine were falling apart. Very quality stuff!



All this right as I passed 350,000 miles!!! On August 27 of 2015, almost 1 year exactly, I drove 30,000 miles. Put her through her paces with a lot of trailers and a lot of hard driving. She did great.
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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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post #9 of 1111 (permalink) Old 07-12-2017, 04:00 AM Thread Starter
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Re: Project Shamu Build

In October of 2015, after doing a lot of research, I installed a RiffRaff 4/4 Billet wheel, looking for some more boost. (I was struggling to make 14-15lbs at the time).




I didn't notice much, and if anything, I felt the motor "slowing down" for some reason, had some issues that I couldn't understand, then one day while out testing to see if the HPOP could hold pressure and determine the health of the HPOP, the truck started misfiring, and BELLOWING white smoke. Uh oh.

Pulled over, popped the hood. No coolant in the reservoir. Pulled dipstick, 6 quarts or so high on oil. Also noticed pin hole in radiator that had been leaking coolant on top of the motor for a while.

And the tear down begins to find out what happened...
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1996 Cali F350 CCFB, 7.3 PSD, 2wd SAS, w/ 372,000 miles.
New Motor at 352,000, DieselSite Legendary Trans at 356,000 and many more


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1983 F150 SCSB Flareside, 302 w/ AOD Trans


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2002 F450 SCFB, 7.3 PSD 2wd w/ 144,000 miles
SOLD
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post #10 of 1111 (permalink) Old 07-12-2017, 12:45 PM
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Re: Project Shamu Build

oil cooler fail?

1997 CCFB 7.3, ZF5, 4x4, 4.10, baby swamps, TS6, E99 spyder, RiffRaff pipes, 6.0 FMIC, RSK, 315 toyo at
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2001 Excursion 7.3, auto, 4x4, 3.73, collecting parts for suspension lift
2000 E350 7.3, auto 2wd, 3.73, toy hauler camper conversion...researching 4x conversion
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