Trying to figure out where to start...

GallopingFord · Nov 6, 2014

So I'm trying to figure out a place to start with my recent acquisition... I picked up a 96 F250 with 382K on it. Everything functions pretty well for the mileage, biggest reason I got the truck was for the solid frame that is practically flawless and it was a RCLB which I've looked for.

So far the following has been done as part of nursing it back to health -
*Flushed coolant
*Oil change
*New Alternator, since the one on it was failing out
*New rear shackle mounts
*New Red Head Steering box

I'm simply looking at what I can do to freshen it up a bit. Stuff I'm looking for pointers -

*I am still searching for a 95-97 Dana 60 and figuring out what RSK/rear blocks and shocks to use to clear 35" BFG tires on the stock Alcoa wheels. I've never owned a truck before (always lowered vehicles) and not sure how blocks/leafs etc work.

*Looking for an improvement of intake filter since the one I have needs to be replaced and not sure if it is worth to just spend money on an aftermarket one.

*Intercooler system that would work with a RSK?

*Diamond eye SS exhaust worth while investment?

*What can I do to touch up/paint frame without undercoating it? One day I hope to strip it down and sandblack/etc but until then looking for something to suffice.

*Worthwhile investment for Injectors on stock turbo?

*Tuning? Transmission tuning?

My goal is to maintain a reliable truck that has a little more pep than it has now. I'm still learning all about diesel vehicles so I apologize in advance if I don't understand some terminology. I'm open to any suggestions.

Thanks -

ThreeFitty · Nov 6, 2014

Okay so I will touch on a few things here, not all...

Intake- search around for the Napa 6637 filter, you can make your own system easily and very cheap and it will filter better than a lot of the systems out there(No K&N on these trucks!!!!)
Exhaust-SS exhaust will do well, 3" downpipe to your choice of pipe size for the rest will do very well.
Injectors-For the most part (unless they are extremely worn out) your current injectors will max out the turbo on a hot tune. Most buy a tuner, then turbo, then injectors and hpop if necessary and in that order. While the AA Code injectors in your truck are as small as they come, not having a wastegate on your turbo from the factory will make lots of power.
Transmission- Not sure which chips/programmers as well as the tuning people actually tune the transmission, especially the E4od in your truck...

Best to just research as much as you can and you will get it all rather soon. Welcome to PSA and the diesel community!!

GallopingFord · Nov 10, 2014

Thanks!

I took a look at the 6637 filter and that looks like a great idea. However is there any kits that actually incorporate the filterminder/iat sensor? If not I'll probably go with this setup.

Problem is with my current injectors is I haven't take a look at them, for the most part they are working relatively well. I do believe I need to replace the glow plugs though since during a cold start up the truck has begun to start and stall and then start again after a couple tries with a bit of white smoke coming out.

I contacted PMF for the 2.25" RSK kit - I'm just trying to make sure that it will fit with a intercooler without modification. Any insight into this?

Jason · Nov 10, 2014

Most who have kept the filterminder have tapped the end of the filter, and installed it there. Welcome to the forum Cam, from another s197 member. Guys, the kids work is legit, you should see his gt500/bullit hybrid lol.

GallopingFord · Nov 11, 2014

Very nice I just came across this write-up - http://www.guzzle7pt3.com/filtermind.php

Also, thanks for the compliment - I'm sure this truck is about to be another money pit for me.

ved0303 · Nov 17, 2014

i love my diamond eye exhaust. Also, I run 35s with little to no rub and mine is just leveled.

GallopingFord · Dec 3, 2014

ved0303 said:
i love my diamond eye exhaust. Also, I run 35s with little to no rub and mine is just leveled.

I was looking at that or the MBRP 4" in Stainless Steel.

After doing a bit of digging and research I think I'm set on the PMF 2.25" RSK and SD V Code Leafs in front and SD U Codes in back with 4.5 or 5" block so there is a small rake.

Decided not to worry about an intercooler system for the time being... just going to do exhaust, stage 1 injectors (and new glow plugs at same time), and Dana 60 this winter. Worked on the truck yesterday and almost thought the oil pan was leaking at the seal but think it was due to no o-ring being installed on the dip stick tube. Next week when I have time I'll be wire brushing the frame and painting it to the best of my ability... still looking at what I can do for that.

6.4Ltony · Dec 3, 2014

I am new to obs trucks as well. here's what I have done on my 96
1. Intake advance diesel intake
2. CCV. Get new intake boot from intake hoses.com. Mod stock metal elbow.. I cut and molded plastic blocker plate where crank case tube went in bottom and secured it w factory screw and secured w permatex rcv
3. If e40d then dieselsite filter and find a good trans shop. I have one...jcar trans in Asheville. Flush. Deeper pan. Bigger cooler.
3. Dieselsite coolant pump w filter..it's a t444e pump w good hoses. Gates has replacement coolant hoses for the other hoses. No replacement T fitting from block tho. Find billet one. I used Rocky Mountain westy... Pricy
4. Paul at complete diesel performance has a great a pillar and foglight mounts. Dudes great to deal w too.
5. Love my fs2500 oil bypass
6. Down pipe and exhaust of your choice
7. I have a ford 10.25 rear. I changed fluid and put ford aluminum finned cover on...same cover on my 2010 250. Cheaper than magtec and others
.....plenty of other stuff as u see fit and based on # of Ben franklins available

Magnum PD · Dec 3, 2014

Your HPOP has got to worn out.

co04cobra · Dec 4, 2014

I make a piece to use the 6637 and keep the filter minder. It's basic same Oem abs plastic, but have been thinking of having a few billet ones made if there's a need for it. I'll try and post a few pics when I get a chance.

GallopingFord · Dec 4, 2014

Magnum PD said:
Your HPOP has got to worn out.

While I'm not sure how many miles it has on it, how could I tell if it is worth replacing?

Arisley · Dec 4, 2014

Gauges, you gotta get gauges.
E-fuel, get rid of that mechanical fuel pump.

Welcome to the site and good luck with your truck.

lincolnlocker · Dec 5, 2014

what he said^^^^ plus this stuff

diy 6637 intake
exhaust
custom tunes

leave it at that unless there is a bigger issue that needs addressed...

if you want more power then add in some trans upgrades, hpop, turbo, and injectors..

live life full throttle

lincolnlocker · Dec 5, 2014

and welcome to PSA!

live life full throttle

superpsd · Dec 5, 2014

Hpop could have been replaced at some time. Injectors as well. Get a scanner and see what condition the heui system and various sensors are in. Honestly on the injectors side I would go bigger than needed and have them detuned. Seems everyone who starts with a basic injector ends up upgrading as everyone always wants more. Worst case is you never need the extra fuel and your wallet was a few hundred less.

GallopingFord · Dec 5, 2014

Any gauge pods for the dash instead of A-pillar?

It kinda sucked that the truck didn't have any maintenance records when I acquired it, with a truck of this age, that would have been nice.

I'd like to do the E-fuel upgrade but not at this moment. Main goals is just to have a reliable truck that runs well. I don't need a ton of power - I already have two toys that fill that void. Just need to find a starting place on the truck and go from there. I doubt I will be towing with it anytime soon, but would like to in the future.

So far this is what I have though for priorities -

Engine
*Needs Glowplugs
*Gauges
*6637 Filter/Intake
*Straight Pipe Exhaust (MBRP/Diamond Eye)
*6pos Tuner
*Possibly Injectors (looking at Baby Swamps)

Suspension
*RSK 2.25"
*Dana 60
*V and B code Leafs
*Bilstein Shocks
*35" Tires on Stock Alcoas
*Drop track bar bracket and adj track bar

Misc
*Wire brush frame and rust reformer/solid black paint over it
*New rear diff cover since it is rotting through
*Needs a new core support with front cab mounts
*Cab corners replaced
*Retrofit power locks/windows and mirrors
*Retrofit cruise control
*Looking for XLT exterior trim
*New tailgate
*40/20/40 bench seat w/ arm rest

superpsd · Dec 5, 2014

Stick to motorcraft for the glows.

cbf9703 · Dec 5, 2014

GallopingFord said:
Any gauge pods for the dash instead of A-pillar?

It kinda sucked that the truck didn't have any maintenance records when I acquired it, with a truck of this age, that would have been nice.

I'd like to do the E-fuel upgrade but not at this moment. Main goals is just to have a reliable truck that runs well. I don't need a ton of power - I already have two toys that fill that void. Just need to find a starting place on the truck and go from there. I doubt I will be towing with it anytime soon, but would like to in the future.

So far this is what I have though for priorities -

Engine
*Needs Glowplugs
*Gauges
*6637 Filter/Intake
*Straight Pipe Exhaust (MBRP/Diamond Eye)
*6pos Tuner
*Possibly Injectors (looking at Baby Swamps)

Suspension
*RSK 2.25"
*Dana 60
*V and B code Leafs
*Bilstein Shocks
*35" Tires on Stock Alcoas
*Drop track bar bracket and adj track bar

Misc
*Wire brush frame and rust reformer/solid black paint over it
*New rear diff cover since it is rotting through
*Needs a new core support with front cab mounts
*Cab corners replaced
*Retrofit power locks/windows and mirrors
*Retrofit cruise control
*Looking for XLT exterior trim
*New tailgate
*40/20/40 bench seat w/ arm rest

A chip and babies from Swamps is a good starting set up. Nice injector for a slight pick up in power and mpgs with stock oil.

Where are you wanting to install gauges on the dash instead of A pillar? The pods that wrap the steering column for SDs don't fit as nicely and block some of the gauges and lights. Not sure if that option is out there for OBS, since mine came with gauges and I don't plan to replace them anytime soon. There are gauge pods that mount on top of/under the dash, but the A pillar is generally a cleaner install IMO.

GallopingFord · Dec 5, 2014

superpsd said:
Stick to motorcraft for the glows.

Wouldn't ever think otherwise. I work for two Ford dealerships (and a Chevrolet store) and I value OEM quality very much.

cbf9703 said:
A chip and babies from Swamps is a good starting set up. Nice injector for a slight pick up in power and mpgs with stock oil.

Where are you wanting to install gauges on the dash instead of A pillar? The pods that wrap the steering column for SDs don't fit as nicely and block some of the gauges and lights. Not sure if that option is out there for OBS, since mine came with gauges and I don't plan to replace them anytime soon. There are gauge pods that mount on top of/under the dash, but the A pillar is generally a cleaner install IMO.

That's the thing, I haven't see too many other setups, but I just do not like A-pillars. For example, I had something custom made for my 09 Mustang since I did not want a A-pillar. Overhead gauge pod in the map light -