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Discussion Starter #1
Hello!

My name is Jamie, or 410Custom's as I appear online

I am a Ford fanatic and off road aholic
I build all sorts of stuff in my private home shop
Mostly ranger based trucks, but we also do ATV's, UTV's, Sleds, campers and more.

I just sold my 2000 F250 V10 Superduty flatbed with low miles on it, well actually I traded it straight across for a wicked cool 2001 Excursion 7.3 turbo for the family (we have been after one for some time)

I was able to sell my flatbed (base of shop operations) because last year a 1997 OBS 7.3 long bed 4 door fell into my lap. Well was actually towed to my house and I bought it for $3000
201K miles. Lots going for it, new Michellin 10 ply's, recent driveshafts, very straight cab and more

That brings me here
I am going to need some help.
I am new to Diesels but I learn quickly

So here she is! My next build/new baby /shop /work /tow /firewood atv hauling diesel truck

Backstory:
When she landed at my house it was because I towed it home 5 miles with my V10.
This thing broke down at the bottom of our hill. My stepson bought it and was bringing it here to show to me. It did not make it. Instead the low oil shutoff safety shut the truck down. It has burned all of its crankcase oil as fuel and was now out of oil.
Long story short my stepson got some of his $$$ back on the deal and was going to sell the truck (Not interested in repairs)
So here it sat....at my house.... looking at me
I have always wanted a 4 door long bed diesel
So after researching the 7.3, injector O rings and such I bought it. $3000 and she was mine.
I put two interstate batteries I had lying around in it
fresh oil change
new fuel filter in the bowl (cleaned heater and bowl)
New Alliance O rings on all 8 injectors
7 new Motorcraft glow plugs (8th is swollen, broken and not coming out)
New Dorman valve cover gaskets (whoops these are cheap!)

And she was running! She starts right up and runs on all 8. Has good power

But the ZF5 trans was LOOSE as a goose....hard to find the gears. So I parked it for the winter and began to save $$$$.
I bought a Zf5 rebuild kit, Luk Clutch, Luk Flywheel, & Luk hydraulics

Then I never found the time to rebuild the zf5. UNtil last month, I found a rebuilt Zf5 from a 460 truck and bought it.

Last week I installed the rebuilt 460 version Zf5 into the truck with all the new LUK parts. It works awesome!! 5.72 granny gear is nice!
Yes I had to drill the bellhousing, no it was not difficult. I used a hand drill and it took all of 30 minutes.

Hooray I now have a working truck! I went and got temp tags for it
I welded the broken radiator support together. Picked up a replacement hood, headlights and header panel and that's where I am today.

Truck blows LOTS OF GREY SMOKE at cold start, 10-15 minutes worth. Runs rough for a minute then smooths out. Loud knock, but not much different idle from other 7.3's we have around here.

I have NOT put it under heavy load or even driven 50 miles since the injector O rings

Grey smoke never totally goes away, however when its warm it runs fairly well and only a little blue smoke

I am ready to spend some $$$ and tear into this 7.3
My plan is

1. compression test
2. new injectors (160cc or so)
3. rebuild turbo w new wheel
4. re seal pedestal, EBPV delete
5. Motorcraft valve covers & wire harness (1997 harness needs lots of repairs)
6. TS6 chip & Tune for 160cc


and more
Diesel fuel in the fuel bowl is dark
I believe it is still burning crankcase oil
Does not appear to be using coolant, but coolant is dark

Any advice? Rip the 7.3 out and go 5.9? Wait for results of compression test and go from there?
How do I know if oil cooler is mixing?
injector cups leaking?

Thanks for any advice! PLEASE HELP ME SPEND MY $$$$ AND TIME the best possible way!!

I have less than $4000 in the truck today, it has a temp tag. I have a $2500 budget for this next stage of work (including windshield) and I have 30 days to pass emissions
 

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Discussion Starter #2
Today I am installing new header panel, Ebay headlights and Riffraff turbo intake boot (stock orange is ripped)
 

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Discussion Starter #3
I cannot post pictures.....that sucks
Sorry for the novel
Looking forward to having this thing reliable and straight so I can put her in service
 

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How many miles on the truck? Do you smell diesel in the coolant?
Check play in the turbo. In and out and up and down
What does the exhaust smell like
 

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Discussion Starter #6
Miles are 201K
Turbo rebuild kit with billet wheel is on its way. This turbo is stock and the wheel has been dusted a bit. I did not check play instead I am going to remove it and rebuild it.
EBPV delete using 3/4" freeze plug and 1/4" pipe plug
Pedestal and rod are leaking
Exhaust smells like un burnt diesel, not sweet like coolant.

I have been monitoring coolant level and it is good, coolant flowing through overflow is nice and green
Fuel bowl, diesel fuel is dark colored in bowl
Crankcase oil appears to be going down, however I have not been able to drive it much yet. Yesterday the oil level was at the "add" mark so I added 2 quart treatment of Stiction remover.

I believe all 8 injectors are firing, but one or two may be sticking
I have 7 good working glow plugs (8th is swollen and broken off could not get it out)
I will be doing a compression test, I am building the adapter now


Thanks for any help!!
 

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Discussion Starter #7
here are some pics of my progress
 

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At that mileage your injectors could be bad. Especially if it was poorly taken care of.

I would invest in a way to scan your truck, if you don't have one already.
Autoenginuity is great. I personally use forscan and a obd2 Bluetooth adaptor.

Instead of using the 3/4" plug for the outlet. Tap it to 1/2" npt. And toss in a plug.

How are you sealing up the glowplug that broke? I wonder if you have low compression on the cylinder due to that.
 

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Discussion Starter #9
more drilling the gasser trans

OEM 7.3 trans broken tailhousing cracked bellhousing (very nice repair here)
I already sold this core and BW rebuild kit I had on Craigslist

I re ringed the injectors last year and installed the Dorman valve cover gaskets / wiring repair. I wish I would have used Motorcraft gaskets, but we will see how long these hold up

The radiator support was broken when they pulled this 7.3 to replace 3 cylinders/pistons/rods at 150K miles
Nice eh? I welded it back together until I can afford new rad support
 

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Discussion Starter #10
thanks for the tips about the EBPV delete will do, I don't like freeze plugs when a threaded plug can be used.

I have a new Bluetooth ODB2 adapter on the way
We have ONE android style phone in our house and have already downloaded the car gage app = buzz test
Can do my 97 OBD, our new 01 Excursion 7.3, my stepsons 2000 7.3 and my other stepsons 01 7.3 :)

Im working on installing new header panel, Ebay black headlights, grill etc. So I can drive this thing around a little bit!!

I know it may need injectors I plan to buy some when I can afford. Not sure if I want to reman these AA units, or updated to 160cc or what...we will decide that after I fix all these turbo leaks
 

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Discussion Starter #11
more pics. no particular order
 

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Sweet. Check out forscan for your laptop. It will do all the tests you want. If your computer is blue tooth enabled you can use that same adaptor.
 

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Discussion Starter #13
we only have apple products and no bluetooth laptops!! Can I use an Ipad????
Appreciate the help man! I really do

I NEED IT!!!!! I am gonna build this OBS into a reliable hauler one way or the other
 

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I don't think the ipad works.

Maybe start checking craigslist for a cheap laptop.
 

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Discussion Starter #15
here are some of my builds just so you guys can get an idea of my experience level (been building Fords, off road toys for 20+ years)
I specialize in drivetrain conversions, suspension fabrication, custom interiors, etc
My daily driven 1988 Bronco II is OBD2, 302/4r70w/1354m it thinks it is a 98 Mountaineer with a CA emissions legal conversion.
 

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Discussion Starter #16
pics
 

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Discussion Starter #17
more projects

I will see about borrowing/acquiring an old PC laptop, would be useful in the shop for sure as just about everything I work on is OBD2
 

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Discussion Starter #18
onto the good stuff:

Riff raff intake boot installed (factory orange boot ripped)
Rad support welded both sides, new header panel and lights (factory broken)
AFE air filter toast, new replacement on its way

Check out the tensioner pulley and idler pulley!
Notice the pulley on tensioner is HITTING the allen head mount bolt??? Thinking the bolt for the idler and tensioner are reversed???

Trying to find a Zf5 7.3 inspection cover??? Anyone know where to find one

Will start a thread on our new Excursion ASAP!!
 

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Discussion Starter #19
Upon further review:

needs waterpump BAD (rockauto) 1/2" play!!! Whoa
Cowl is loose as a goose (OBS thing?)
Pass front door is FUBAR (junkyard)
Coolant gauge INOP (Use explorer parts I have lots of explorer parts to fix)
One cab marker light is out (Amazon, LED)
Mirrors are aftermarket (junkyard)
Tensioner is loose, needs replace (rockauto)
drv rear brake locks up at touch of pedal (new brakes)
E brake cable/pedal INOP (tear down)
Windshield cracked (new)
drv door panel broken (JY)
Duct tape shifter HAS TO GO
Clutch pedal cover (new)
Needs ac condenser (JY)
Needs ZF5 inspection cover (may fabricate from 460 scatter shield I have?)
Front door pins both sides, possible hinges





Already a money hole, that's okay I expected it....... (Rockauto loves me)

LED bulbs fitted into parking and turn lamps
Looking into LED cube retrofit since I know these cheap black headlights will leak and not throw any light down the road with halogen bulbs


Should take a bit to get her road worthy!!!!!!!!!!!!!!!!!

My theory is:
Assuming my injector O ring re seal I did is holding, the leaking turbo = crankcase oil in exhaust = White smoke at start/running and loss of crankcase oil

Am I on the right path??
 

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I think your doing a great job. I like to see an old pickup get a new life.

Mine needed alot of little things also when I first bought it. Its pretty bad ass now.
 
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