Many thanks to all of the great mechanics out there who have super advice about how to deal with upper end problems in the 6.0 diesel. Here are a few slides to show what we did.
PROBLEM: blown head gasket, bad EGR, FICM issues. The Ford Master Mechanic video series is invaluable.
I will follow up with a second thread later, sort of a "lessons learned the hard way" do' s and don'ts"


http://www.camanosail.com/Slideshow.pdf

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The slide show is about 5 megs so don't get impatient: it may take a minute to load.

 

Nice slideshow! What all crap has to be disconnected before lifting off the cab? Are their good lift points where I can use an automotive symmetrical 2 post lift to pick up the cab?

Thanks,

Keith

 

if you have running boards then you can lift from there, I prefer to pull the engine, can be pulled in about 6 hours with 2 people and you don't have to worry about recharging AC or messing with any of the brake system. Once you lift the motor about 6 inches then you unbolt the AC pump and power steering pump and you are good to go.

 

I have running boards, didn't realize they were strong enough

Can't you unbolt the AC pump and lift it with the cab rather than recovering the freon and breaking the lines? Or am I missing something?

Pulling the engine OR the cab seems less frustrating than doing a major job while trying to work inside the engine compartment. How much does the engine weigh? I don't own a cherry picker yet, so I need one tall enough and strong enough for this... I could probably just pick up my Miata engine but I don't think I could manage that with the powerstroke

Later,

Keith

 

The AC pump is on bottom pass side of motor and the lines are almost solid, you would kink or break something if you pulled the cab and left the pump attached to the condensor. You don't need a special lift, I use one I got from Harbor Freight, it's the fold up kind rated at 2 ton. These engines are right around 1000lbs, I made a lifting plate that bolts to the turbo pedestal mounting surface on the block with 4 bolts, and it also bolts to the oil cooler location with 2 bolts for adde strength. I pull the turbo/intake/oil cooler/unbolt the torque converter/unbolt the trans/unbolt the motor mounts from frame/ take the bolts out of the trans mount in back/remove the radiator support and radiator/ then pull engine. There is only a couple connectors to remove on drivers side to disconnect motor wiring harness. Like I said before once the engine is up a couple inches you can unbolt the AC pump and Power steering pump and let them sit. Also put a jack under front of trans to support it and rais it the same time you raise engine just until the bolts on motor mounts clear so you can pull motor clear of the trans.
I believe more people have access to a motor lift then a nice 2 post lift.

 

Harbor Freight is the ****! May as well have named the place "damn near free tools"

That is where I am getting six 2 ton high lift jack stands. I won't put the truck up on the lift without extra stabilization. I need to pick up some air regulators and an in line oiler from there along with some fittings. I will check the price of a cherry picker while I am there.

Later,

Keith

 

as someone who does head gaskets on these trucks. i find it easier to pull the engine and put it on a stand. I can and have had this engine out and on a stand in 4 hours, engine tore down heads cleaned and block cleaned and new gaskets and head back on and torqued down in a 8 hour day

 

Or have the cab off in 45 minutes....

Cab is coming off of mine next week hopefully.

 

HaHa, let me know how that 45minutes works out, if the cab could be pulled in that time then the whole job should only take 4 hours with a fresh set of heads ready. The nice thing about pulling the motor is that you can also pull the pan to make sure it is clean.

 

I know guys who can have it off in even less time than that. I highly doubt I personally will be able to have it off in 45 minutes, as it's my first time, but I am working side by side with a friend who has probably done 20 of these now. Getting the cab up is quicker than putting it down, since other stuff has to be done that isn't done taking it off, like bleeding the brakes after and such. A technician at a dealership who works on them all the time... 45 mins is about the average.