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7.3 rebuild time

52K views 52 replies 16 participants last post by  Skew12  
#1 ·
Thought some of you might be interested in what my "other" project is ...

Everything started from this thread here
Shudder, low on power, tons of new parts, still issues - PowerStrokeNation : Ford Powerstroke Diesel Forum


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I've been having a lot of smoke/stumbling issues. After troubleshooting/diagnosing we thought that we had some torque converter issues, and a bad injector. With 240k miles on the truck, and having all original stuff still, I decided to do the maintenance and do everything. 8 new injectors, and a new torque converter, rebuilt trans later, it was still there.

:bigcry:

I was done messing around and took it to Ford Dealership to have them do a compression test.

cylinder 8 had ZERO (0) compression. They are supposed to be around 340-360psi. Well that's not good..

Truck was still driveable so I left the dealership after they told me it was going to cost $15,000 to fix it. (new engine/labor) Took it to my buddies shop who helped with the injector install and a diesel guru.

We had the old 7.3 motor out of the truck in 5.5 hours, and torn down in 3-3.5 hours.

Cylinder 8 had some nasty scratching/scoring in it. We figured the rings had seized to the piston, and just scored everything up. The block and cylinder heads are at the machine shop getting prepped for work, and waiting to find out how far we are going to overbore it (.010, .020, etc) so I can order the Ford OEM rebuild kit, forged rods, and ARP head studs.

The truck will also be getting some other nice diesel upgrades. (exhaust, tuner, gauges, etc)

Should be a MONSTER when we are done. :evil:

I'll keep this updated as I keep getting parts/pictures
 
#2 ·
Clean, Clean, Clean while you have that engine out.
 
#4 ·
just power washed the entire engine bay, and there are some certain parts getting a "coating" :evil

Nows a good time to replace the stock air box!
6637 kit from RiffRaff was ordered today, along with about $5k worth of other stuff... HAHAHAHAH :postwhore2:
 
#5 ·
it just keeps getting worse and worse...

UPS train from the west coast to southern IL got de-railed in Montana. All my engine parts wont be here til Monday now.

Also need all new valves. Apparently the old ones didnt have enough material left to do a proper valve job...
 
#17 ·
WOW it got you to! I know right where that derailment happened, there were allot of ups customers with no freight. They hit a semi at a x-ing. He lived to talk about it! ooops kinda got off the subject.:doh:
 
#8 ·
what VW? :pointlaugh:


that's a flat black, fully gutted/caged e30 coupe. Getting a built M50 with ZF trans in it..
 
#11 ·
here is a picture heavy update guys...

motor out of the truck

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getting everything all cleaned up

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did someone say parts?

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radiator and OLD intercooler

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driver side manifold drilled/tapped

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lots more parts

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stock stuff

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new topside creeper

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stock exhaust in a box

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bigger intercooler :evil:

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turdbro

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exhaust backpressure valve in the pedestal

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EBPV and turbo rebuild kits

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old wheel... HOLY CRAP IS THIS BAD!!!

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this is what it is SUPPOSED to look like (a different stock one)

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starting the rebuild

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#12 ·
cleaning everything up

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new parts in the EBPV

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parts are everywhere

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gauge time

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brand new oil pan

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its getting a coat of POR 15 though to protect it

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time to get the engine craddle all cleaned up as well

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time to start wiring this stuff up with baller weatherpack connectors

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#13 ·
who said powdercoating?

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more sheathing and weatherpack connectors

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redid the transmission temperature sensor with a weatherpack connector for super easy hookup and disconnect on the guage pod

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gauge dimmer switch installed

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connectors everywhere

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intercooler pipes powdercoated as well

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as the engine bay sits right now :(

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#14 ·
Nice job updating us and all the cleaning, is your block at a machine shop then?

Ya know, I have to admit, I love driving my truck now but a year ago at this time, my truck was in the garage with parts everywhere just like yours and I miss those days, LOL.
 
#15 ·
block/heads are at the machine shop. BETTER be done Monday/Tuesday.

This is driving me nutz. The worst part is I dont have another car I can drive in the winter, so I'm renting a POS Ford Fiesta. My track car is NOT capable of being out in the winter
 
#16 ·
Are you getting the cylinders sleeved? How about any porting/polishing in the heads?
 
#19 ·
cylinder 1 - 7 got a .010 bore for the new pistons, and then cylinder 8 got a sleeve due to the wall damage from the destroyed pistons.

no porting/polishing, as this is a OEM+ rebuild. Nothing crazy. Everything was done for reliability and small hp increase, and big MPG increase
 
#22 ·
#29 ·
here you go... HUGE update with 90 pictures

picking up the block from the machine shop
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love the new pistons
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gotta get the block up, wrapped, and ready for transport
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prepping the cylinders heads for paint
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new injector cups
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new valves and head decked
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taped and ready to go
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more tape
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first coat of paint
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painting both cylinder heads and getting them ready for install
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#30 ·
the inside of the cylinder heads waiting for the intake manifold plenums
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taping off the block
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more taping
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first coat of blue
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i like blue
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a LOT
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block is ready to get a LOT of parts attached to it
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hello cylinder heads
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2nd coat of goodness
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another pic of the cylinder heads getting a 2nd coat
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#31 ·
all done and ready to go
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untaping the block, almost ready to install the parts
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installing all the lifters, after they were rebuilt by Mizpah Precision in MN. GREAT guys to work with, and they were all done and shipped back for $55 total
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cam installed with assembly lube
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prepping the timing cover with new gaskets/Motorcraft RTV
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Chris from Devo 2ning installing parts/prepping stuff with our "layout/setup"
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High pressure reservoir installed with all new gaskets
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damn that block looks good
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more installing/prep
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installing the fuel bowl after a full rebuild from dieselorings.com
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#32 ·
starting the ARP stud install (all 36 of them, took forever)
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this is taking FOREVER
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really, there are 18 more?
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water pump and crank pulley installed
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prepping the surface for the cylinder heads
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copper coated OEM gaskets installed
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both sides
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all ready to go
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block begging for more parts
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cylinder heads inbound
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#33 ·
box is starting to get thing from installing all the parts finally
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cylinder head time, YES!!!
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both cylinder heads down
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torquing everything down
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installing the inspected pushrods and rocker arms
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installing fuel injectors
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gotta get all of them in
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I like ARP studs
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damn this thing looks good
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cant wait for it to get in the truck
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#34 ·
getting the valve cover harnesses installed
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plugging everything in
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$.50 mod
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valve covers on and torque'd
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exhaust manifolds installed, with driver side pyrometer for EGT gauge
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this looks amazing
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can't wait until its all back together
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Riff Raff Diesel FPx
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fuel bowl heater replaced
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cant wait to fire this up
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#35 ·
Riff Raff diesel high pressure oil crossover
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REMEMBER TO INSTALL THE INTAKE MANIFOLD BEFORE THE TIMING COVER, OIL RESERVOIR!!!!!
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grrr... pain in the butt
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Riff Raff Diesel manifold reinforcing plenums
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finally starting to come together
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motor back on the engine hoise so we can get the rear main seal and bracket installed
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back to the engine stand
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getting there... oil pickup
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POR 15 covered oil pan going on with LOTS AND LOTS of RTV
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torquing everything down with new OEM bolts
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#36 ·
use that RTV on the pan, It WILL LEAK if u dont
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test fitting the turbo/spider
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i like the way this is coming
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new boots installed
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checking the fitment of the oil crossover
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up-pipes installed
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getting the flex plate installed with a spacer
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looks good
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sorry for time lapse, I was under the truck helping get everything aligned on the crossmember, and in the trans with torque converter all lined up. WHAT A GIANT PAIN IN THE ASS


motor is back in the truck
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damn this looks sexy in the truck
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#37 ·
got the power steering pump bracket installed with the AC compressor bracket and belt installed
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installing the diesel site coolant filter
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6.0L Mishimoto Intercooler installed with the crossmember
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wow this looks good
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getting the bracket for the filter all rigged up
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this thing is massive
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prepping the area for intake installation
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radiator and expansion tank in there
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another view
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all back together. This looks great
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