04 motor into a 06
 

My 06 motor had a super sweet lifter failure so i can only imagine how the inside looks. My only resort it to go with a guy who has a 04 motor. I plan on getting it down to a long block and getting a master solution kit from MKM with the black diamond HG and the update kit as well as the Ext oil filter and ext coolant filter. The gentleman is keeping his turbo, ficm and injectors. I have access to the proper tools and place to perform this want any input. Also i am planning on rebuilding my turbo with a batmo wheel, lifters and sending my injectors to RCD for a rebuild making them 90hp injectors. Also as far as the hpop and intake and wire harness off my 06 i plan on keeping all of it but the hpop out of the 04 is the earlier one so i my 06 one useless? what intake pieces are different ( wont bolt up properly). My harness i know i will have to reuse but will i have to mod it at all. just trying to figure this out as of right know this is my only option :argh:

stick with Ford head gaskets, they are the best made, others have had several issues. the factory bolts were the issues, not the gaskets.
You can use your 06 heads on the 04 short block and swap over the High Pressure oil Pump and the branch tube from the 06 motor to the 04 block. I put the 05 pump and branch tube in my early 04, it all bolts up the same. this way you won't have to reroute the ICP sensor pigtail, the only wiring that is different between the 2 years.

so the 06 hpop with the STC fitting all have a place to boltup? and which one is more effiecient the new or older style? With the heads isnt there a different dowel pin size? i just wanna get these hashed out before i get the motor

Early motors were 18 mm dowels, newer ones were 20 mm. Gotta measure yours and by all means, use ford head gaskets.

I feel that my truck runs better with the newer style pump in it, yes your 06 pump will bolt right up to an 04 block, the main thing is you have to also use the 06 branch tube, there are 3 different branch tubes 1-03and early04/ 2-late 04/ 3-05 and up. the new head gaskets come with dowels that are 18mm on one side and 20mm on the other as well as either 18mm or 20mm. they switched to 20mm dowels sometime in 06

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If you realy want to keep it simpler then you can still use the 04 heads on the 04 motor and just change the rocker boxes, if it is a late 04 motor with the pretzel style oil rails then you don't even have to change them, you will only need to change rocker boxes if you have the 03-early 04 log style oil rails. the older rocker boxes don't have the top bolt holes to mount the newer style oil rails.

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Sorry, you also have to use the proper glow plugs and glow plug harness, I am pretty sure the 04 and 06 plugs are different and you have to use the proper harness for the year of rocker box you use,

Glowplugs
 

So with all this being done i plan on replacing the glow plugs as well, so i know the sizes were different in the early models as opposed to the late models. so with 06 heads on an 04 block which glow plugs should i get ?

06 heads =06 glow plugs