Upgrading to the Superduty UVCH + valve cover gaskets:
Removed the engine harness:
..and rewiring it for the SD valve cover gaskets:
...and all done!
With that done, all that was left was to install the harness, batteries, fender liner, and throw some fluids in it! So i got all that done today, purged the fuel lines, and got her running!
...Then i went thru the yard, and filled the bed of the truck with downed branches from the winter
So i figure ive got a good weeks worth of work of cleanup to do, but i expect to be working on the big bronco again before the end of the month!
Made some progress this morning, before the weather turned sour.
Exhaust manifold in, along with up-pipe, which you totally cant see, but its in there!
check these rocker arms!
Valve train installed. Down-pipe is reinstalled too.
All new orings and washers on the injectors:
I got all the injectors reinstalled, but by then it was raining pretty heavily. Hopefully tomorrow its a bit dryer out!
Figured the head was off, might as well do valve stem seals:
I had one cracked injector cup, so i replaced all 8
7.3 has a two-stage fuel pump in the valley, and uses a single hard line to supply fuel to the back of both heads:
I wanted to replace mine since it has a kink on the passenger side, and the rubber collars behind the nuts are rotted after 24 years. Well, you cant do it with the turbo installed!. It also uses the biggest banjo bolt youve ever seen!
i had to order a set of metric 1/4" drive swivel sockets to get the turbo out, as nothing else will fit in there to remove it. It is god damned tight in there:
That wasnt the worst either. No way to do it w/o them swivel sockets.
Turbo out, new fuel line + pedestal o-rings installed:
...and finally, turbo reinstalled!
Got all that finished up this morning. Weather permitting, monday morning i should be good to start reinstalling the head!
I broke a glow plug a couple weeks ago when i was trying to replace them. Couldnt get the last piece of it out of the head, so.......
That was yesterday. Hopefully next week ill be able to put the head back on. OEM head gaskets & bolts, OEM exh manifold gasket & bolts. Had a cracked injector cup so theyre all getting changed (bought the kit from Rosewood Diesel to do it). Doing valve stems seals, because she's at 201k & the head is off so why not. Also have the parts to convert the truck over to the Superduty valve cover gaskets + UVCHs (Under Valve Cover Harness for you non-diesel guys).
So the dump bed works pretty awesome!
You cant really tell, but theres a yard of stone in the bed.
I didnt shoot any vid of it dumping, didnt think of it at time, was more concered with watching it, since a yard of stone is ~2600lbs. ive used it a couple times now, it is super awesome.
The green tailgate presented a problem though. It was a necessity as my original tailgate got smashed, but its bowed pretty badly, and i was losing stone on the way home. So, i dug out a shell ive had kicking around, and decided to see what i could do with it.
Made some progress on the water/meth injection! My wiring harness uses 7 wires, so rather than build an extension, i bought 7 wire trailer harness:
More OEM wedgelok pins being put to use
Original harness on the frame:
...and the new extension plugged in and looking OEM
The harness runs up the bed here. Next to it is a hydraulic hose connected to some 3/8 stainless tube via some swagelok fittings for the water.
The route up the bed:
Another OEM connector, where my extension harness ends in the toolbox. In the top left you can see where the tubing enters the box. 100% stainless tube from the bed hinge to the toolbox.
The original toolbox harness modified with a mating wedgelok connector installed:
...and the whole water/meth system is now reinstalled and done!
I turned the system on to check for errors and didnt find any, so i removed/cleaned the injector and then purged the system. Holy shit i think were done!!! I still need to find a place to relocate my CB antenna to, but aside from that she's 100% done!
After sitting for 7 weeks under a black walnut tree the truck needs to go to the carwash pretty badly, so i guess thatll be my test drive to see how badly the bed rattles around.
The kit comes with these guides to keep the front of the bed aligned with the cab, but i never installed them because my hinges are so much more sturdy than the ones that came with the kit, and the bed doesnt flop around like it woudve with their hinges. So we'll see after the test drive (hopefully tomorrow) if i need to put them on or not.
Bought a piece of unequal angle (3x4) from the scrap steel yard to begin mockup for a bumper
So heres the rough idea:
Seems awfully small, but with the bed tilted, you can see its a tight fit
No room for a license plate on the bumper
Trimming the corners
Adding a piece of 2" plate to the bottom
Now its starting to look like something:
All done and ground
For lack of a better place, i put rivnuts in the tailgate, to hang the plate off it. This gate is beat up anyway, so not too upset about drilling holes in it
All done & painted!
While i was waiting for it to dry, i fixed my trailer wiring. Turns out Clips & Fasteners sells replacement pins for Ford Wedgelock connectors. Male + female, and both the large and small pins. They get crimped on using the same tool as weatherpaks do, which i already have. Since i had broken wires i cut all of them back to fresh copper and repinned all of them
So all thats left is to bolt it on, and its done!
Its a tight fit against the hitch:
Look closely, youll see the bumper brackets all but touch the hitch, and there is actually a vertical groove in the bumper to clear the hitch. Its tight!
The bumper is a little smaller than id prefer, but as big as i can make it. Overall i think its looks pretty good on there though. So thats two more items off the list! So next week i need to tackle the water/meth injection, move my CB antenna and then i think im done!
Ok, so weve got 4 main projects left to finish this thing. Gotta solve the bumper problem, fix trailer plug wiring, rewire/plumb the water/meth injection, and relocate the CB antenna. Well, ive got 2/4 done now.
All this work on the bed; so i decided to work on the bumper. Since its got to pivot with the bed, i started building brackets to attach to the hinges:
One bracket done, shown attached to the bed-side half of one of the hinges. It attaches to the 5/8 hinge pin, plus 2 bolts up thru the hinge and into the bed. Should be sufficient.
Both brackets done, + hinges finally in paint!
Now to design a bumper.
Ok, filler necks!
Well, they bolt to the bed. But they cant since the bed moves. So Pierce Arrow wants you to build a brace and aim them both into the wheel wells to fill the tanks. Lame! So i came up with an (arguably) better solution.
Starting on the rear neck:
Built this, which didnt work. The fender strut hit it.
Had to cut the hole for the filler wide open, but you cant see it with the filler door closed anyway
This actually works; the bed can go up and it holds the neck in place; when the bed comes down it guides the neck right into place. The front was much more challenging. The bed full on collides with the neck and pushes it down:
So this is what i came up with
It holds the neck right where it needs to be. But, because the bed hits the neck on the way down, you have to hold the neck up and tuck it behind the fender as it comes down. Then the bracket guides the neck into place:
No way around that one, w/o cutting a notch in the bottom of the fender to clear the neck, which i think would look dumb.
Ok so then i got to looking at the bumper. Well, no chance in hell of the stock bumper going back on. The bumper has to tilt with the bed, and there is just no room with the trailer hitch there.
Mockup with a peice of 2*4 to simulate a bumper:
Im going to have to build my own rear bumper, and its going to have to be small, so it clears everything. I also still need to re-do the water/meth injection & move my CB antenna, but i think that might be it!
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