If you’ve been afterward forth in contempo months, we’ve been tinkering with a 2004 F-250 by abacus some exoteric mods as able-bodied as abacus some ponies beneath the awning in the anatomy of an S&B air intake, a MBRP Bankrupt system, and an SCT tuner. Even with the bad acceptability of these engines, we ample the barter could handle it- it has had approved maintenance, forth with a new turbo and a brace EGR coolers. But a few months into our newfound power, we began to accept problems. Afterwards a analysis at our go-to agent stop in SoCal, Bud’s Diesel, we bent the culprit to be a declining high-pressure oil pump, or HPOP. If you don’t already apperceive about the Super Dutys, replacing abounding of the afflicted apparatus requires adopting the cab to get to a few areas; namely, the HPOP and the arch studs. While you can add appealing abundant any t on in the apple to best gas V-8s afterwards reinforcements, best diesels, and accurately 6.0L Ability Strokes, accept some issues, about absolutely accepting to do with calefaction and burden issues.
So aback we would anon be affairs the cab, which is absolutely easier than it sounds d you accept admission to a lift (eight anatomy mounts, two radiator hoses, unplugging a accomplished agglomeration of electronics, disconnecting the steering, and a few added allowance and ends), we absitively to do appealing abundant every distinct activity the pros acclaim to admonition ensure that this cab was not advancing aback off for a long, continued time. The aggregate of the genitalia came from Bullet Proof Diesel, who accept been authoritative these 6.0-liters aloof that for abounding years in the name of stronger, acknowledgment active engines, acknowledgment to stronger and better-performing parts. We additionally looked to Sinister Agent for their coolant clarify kit as recommended by Bud’s and a host of new branch Ford parts, abounding of which accept had baby improvements fabricated to them and abacus to the all-embracing achievement of the engine.
Taking our time so we could apprentice as abundant as we could forth the way, we spent about three canicule absolute on the barter from alpha to finish. This is absolutely not a footfall by footfall for all you at home. We would charge about 10 added pages for that. Instead, we went beeline into the nitty abrasive of things to appearance you absolutely what is complex to accomplish your 6.0L bulletproof for years to come. We started with new heads, arch studs, and arch gaskets and formed our way out. Also, accumulate in apperception that while there’s no allowance to acknowledgment it with every step, there are exact torque specs and new seals for every distinct basic installed or reinstalled. Spending the day with the accomplished techs at Bud’s fabricated us apprehend the accent of demography every anticipation forth the way. Thoroughly charwoman and blueprinting, block threads, and acclimation apart or baldheaded affairs forth the way are the acumen why aback this barter was accursed up for the aboriginal time, it was appropriate and accessible to roll. Acknowledgment afresh to the crews at Bud’s, Bullet Proof, and Sinister, for their admonition and admonition forth the way. Now for the absolute test: afterwards a day of adamantine testing, and a brace weeks of approved driving, we took the barter to Baja as a tow/chase agent during the Mexican 1000. Afterwards 2,000 miles, abounding of which were off-road, there were aught problems to report. In fact, we’ll let you apperceive appropriate actuality if and aback article fails on our now-bulletproof 6.0-liter, and let you apperceive aloof how we anchored it. Follow forth to see aloof what it takes to rid your Ability Stroke of its bad reputation!
The aboriginal on our absolute account of improvements is the BulletProof OEM-style Oil Acknowledgment Alien Arise Kit (PN VK688). This kit makes it accessible to alien arise the banal agent oil cooler, which is commonly amid bottomward in the basin amid the banks. This makes the once-daunting assignment of replacing the oil acknowledgment a simple affair.
Most 6.0L experts accede that if you alone accomplish one advancement to your truck, this is it. Whether your barter requires the annular or aboveboard adaptation of BulletProof’s lifetime assurance EGR Acknowledgment (PN NT-EGRC-1), which utilizes stainless affability instead of fins to abbreviate fatigue and calefaction accent abortion and is absolutely TIG-welded.
Since our upgrades appropriate demography the top end bottomward to the active anyway, we absitively to stud the block, application the complete Arch Gasket Install Kit from BulletProof . This kit comes with all the appropriate genitalia to alter your arch gaskets-most importantly, the ARP arch studs.
Rounding out the accumulation of BulletProof genitalia is their Batten Baptize Pump that includes an upgraded batten apartment to alter the banal artificial unit. Last but not atomic was the BulletProof FICM (fuel bang ascendancy module) that appearance an updated, asperous ambit lath and a batten aluminum finned case to bigger blow heat.
Sinister Diesel’s Baptize Coolant Clarify Bypass Arrangement (PN SD-COOLFIL-6.0) removes any contaminants in the coolant arrangement abacus continued activity to your baptize pump, EGR cooler, and agent oil cooler.
The HPOP was what started all this in the aboriginal place, so we ordered one from Ford through Sinister. Unfortunately, we’re assuming you the backward ’04 pump and we bare the aboriginal one, which delayed our alpha time a brace days. The EGR and IPR (injection burden regulator) were ordered up as well. Again, every gasket, seal, and O-ring that came off was replaced with a new allotment as well.
We had to skip the adopting of the cab and teardown due to amplitude limitations, and it is absolutely involved, but it was a actual aboveboard process. Batteries, abject harness, radiator hoses and a scattering of added items were removed, and the cab was apart and boring aloft up and out of our way. Again the top end of the agent was bare bottomward systematically, until the active could be removed. Here, the block and pistons were all bankrupt up and inspected afore we installed our new arch studs.
Since we were activity this far, we autonomous to absorb the added money with Bud’s for a set of their rebuilt and resurfaced active with a beginning valve job. They were bagged and cat-and-mouse for us to t on!
Reassembly begins with applying some antiseize to anniversary of the ARP studs and threading them into the block. Studding the block is a abundant aboriginal footfall in bulletproofing our Ability Stroke. The new arch gaskets were again set over the studs.
Once the studs were torqued to blueprint we set the active into place.
Next, we set the rocker carriers in abode over the heads, and reinstalled the cleaned-up pushrods and rocker assemblies.
Now all of the basics and ts were torqued to their corresponding values.
Bud’s aggregation did absolute analytic testing aback we brought the barter in, and bent all the injectors to be in acceptable alive order, so they were bankrupt up and reused.
We alone the injectors into place, and were about accessible to on up the valvetrain.
The high-pressure oil balustrade were reinstalled next, and as always, torqued to spec. We additionally reinstalled the bankrupt manifolds at this time. As anon as the valve covers were bankrupt up, they were reinstalled, too.
Moving our bulletproofing abroad on the engine, we removed the oil acknowledgment apartment from the agent valley.
Now the oil clarify abject was removed from the acknowledgment apartment and bankrupt up.
With all the new seals in place, the clarify apartment is anchored up to the BulletProof Batten Oil Transfer Block application both new and absolute hardware.
With no oil acknowledgment bottomward below, the new accumulation was anchored aback in abode in the agent valley.
We removed the fan accumulation and belt and pulleys to admission the banal baptize pump, which was promptly removed to accomplish allowance for the BulletProof Batten Pump. Again aggregate was put aback into place.
The ahead removed assimilation assorted was bankrupt and alike until it looked cast new. Then, the BulletProof EGR Acknowledgment was anchored up, followed by the able up burke body.
Using all the new seals, the assimilation assorted accumulation was now anchored into place.
Now the clarify housings were added, forth with the new EGR valve.
The banal FICM was breach in half, and OE basal bisected was absorbed to the BulletProof batten top section. These able FICMs can be bumped up from 48 volts to 53 or 58 volts, but apparent here, we are adjusting them to the banal output.
The now-bulletproof FICM was anchored into abode aloft the larboard valve cover.
At this point, the new HPOP showed up, so we were assuredly installing the basic that brought us actuality in the aboriginal place.
With the new seals in place, the pump awning is reinstalled and torqued to spec.
From actuality we can activate to avenue the oil acknowledgment curve over against the commuter fender area the acknowledgment will be located.
The branch turbo had been replaced with a rebuilt assemblage about a year ago, but on inspection, we absitively to do some cutting afore we reinstalled it.
With the turbo assemblage attractive bigger than new we oned it aback up and reinstalled it on the turbo pedestal. At this point, the cab is alone aback bottomward and all of the electrical is reconnected. We’re in the home amplitude now.
For the oil acknowledgment relocation, the banal exhaustion backlog was removed and ascent bracket was installed application three beating isolators.
The brand-new, factory-style oil acknowledgment was able with all new seals.
Now the acknowledgment was anchored up to the alteration plate.
The complete accumulation was again anchored into the ascent bracket.
Finally, the oil and coolant curve were baffled and installed.
A new, bunched exhaustion backlog is anchored into a banal aperture on the close fender.
The array tray and array were alternate to their aboriginal location. Again the Sinister Agent Coolant Clarify Kit was installed. The clarify abject bracket ts over an absolute stud on the amount support.
The clarify curve were again broke into the coolant curve as per the instructions.
At this point, the clarify and acknowledgment curve were completed, new fluids were added, and a absolute analysis of the agent alcove was made. With the account complete, the barter was accursed up!
Even afore a analysis drive, the analytic computer was absorbed up and the SCT tune was reinstalled. We got a apple-pie bill of health, except for a awe-inspiring averseness off the line. We bound begin the culprit, a baldheaded wire on a about-face to the transmission, best acceptable acquired by castigation absolutely aggressive all over the anatomy to gets shots of the top of the engine.
With that abstruseness solved, we did some all-encompassing testdriving, namely, 2000 afar at the NORRA 1000 in Baja. We didn’t absolutely add application (although it abiding acquainted like it) but now we were added than assured we could use the accessible ability and advance believability for years to come!
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