Bulletproof Oil Cooler +/- Aluminess bumper- you experience

[dparkwy]

Ketcham,

That's is quite the list for your mechanic! Just an fyi on the blue spring kit: I found that there's a separate part number for the e-series kit vs the f-series kit. Part number 4C2Z-9T517-AA. It does not include the housing or some other extra o-rings which I think is included in the full f-series kit. Probably a touch cheaper because of it.

Also found this Ford Diesel Sales Reference Manual handy for parts numbers, etc

http://www.powerstrokediesel.com/docs/DSRM.pdf

[Ketcham]

Appreciate the manual link.

If I am pulling the motor, I am not leaving a stone unturned and addressing any and all potential issues.

-j

[JoeH]

Good luck with the rebuild. I'm still curious how many miles are on your rig as you embark on complete tear-down?

I did the BPD billet water pump when I did my Delete and it's a work of art. It's a pity you never see it. I'm also excited about the your choice of the KC Turbo 1.5 Stage. I found Charlie extremely helpful when I was considering a turbo upgrade or reconditioning. Because I didn't know exactly which size compressor wheel I had he sent me both just in case. That's CS.

[Ketcham]

25,500. You would think I take piss-poor care of it. Maybe I have and I was ignorant to my ways. Once I have a diagnosis for the failure, I will give my advice here.

I was getting turbo underboost and fuel pump circuit high often. I believe the humid cold NW winters rusted the actuator on my turbo. Depending on condition, it may be an all internal rebuild with billet wheel and titanium veins or a KC turbo.

Uncertain the cause of the injector failure then engine failure:

Hypothesis:
Infrequent driving in the winter (but have trickle charger on engine batteries linked into our house system, I plug into the AC, when the AC is plugged into the residence). Still try to drive it bi-weekly but sometimes monthly.
Bad battery voltage and failed FICM
Bad Diesel fuel
Bad-not sufficient maintained Amsoil oil.
HPOP fitting failure.

Reading on the new Ford engines, I am glad I have a 6.0!

I am very grateful my motor failed here and not some far off land.

I will report my findings and what was done. Rather not see my mistakes (or not) be repeated by others.

[JoeH]

I'm not sure what titanium veins are but I almost put in a new billet unison ring from KC turbo. Mine wasn't corroded so I didn't do it. http://www.wpediesel.com/index.php/turb ... e-crk.html

If you decide to recondition the turbo make sure the rebuild kit has the 360 thrust bearing. It flows more oil.

I love the 6.0 powerstroke. Fun stuff

[Ketcham]

Found out my AIRDOG II died after 10K miles and 18 months of use.

If you use and AIRDOG, carry and extra motor AND install a fuel pressure monitor!

This cost me a set of injectors. (I was planing on pulling the motor anyway).

[JoeH]

Originally Posted by Ketcham

Found out my AIRDOG II died after 10K miles and 18 months of use.

If you use and AIRDOG, carry and extra motor AND install a fuel pressure monitor!

This cost me a set of injectors. (I was planing on pulling the motor anyway).

Dang, so the Airdog did exactly opposite of what it is supposed to do which is prolong injector life?

Looking on the bright side, with all the performance mods you already have combined with ARP headstuds your 6.0 is going to be a beast. I'd go for a 100 HP PCM tune at a minimum. And definitely upgrade to the 1.5 stage turbo. Stock is not going to cut it. You will blow the Camaros, Chargers, and Mustangs off the road when you stomp on it. BEAST MODE

[Ketcham]

Check this out:

https://www.facebook.com/photo.php?fbid ... =3&theater

https://www.facebook.com/photo.php?fbid ... permPage=1

The advantage is having a Fuelab threadless motor with improved reliability.

Seems both FASS and AirDog are having reliability issues. If you have one of these units, carry a spare motor and filters. May just consider carrying a whole entire extra unit. (Yikes) But I read an internal valve can fail sending 95% of the fuel back to the tank and not to you engine.

My learning point is installing a fuel pressure gauge.

[BroncoHauler]

FWIW, my Air Dog has been problem free for 25,000 miles.

[Ketcham]

How many years have you had it? Or could be you have a well built recently built unit. The thoughts on the diesel forums are the newer units have issues.