Early 99 F-550 needs a fresh bullet...need info.

[ktmlew]

Prod date 6-98 F-550 Auto.

 

Have a guy that bought this to build a service truck. Will have a service bed/compressor/welder and eventually a crane. Of course the air-box tabs are broken and intake hose is completely ripped through on bottom...it wouldn't start w/o use of ether. Glow plug relay was not being grounded by PCM. Tested all circuits with B/O box which points to bad PCM. When it did run it wouldn't rev above 1200 and wouldn't idle. Buzz test "sounds like" five injectors are tired.

 

Pulled GP's and ran a comp test. Five holes @ 415-425, two @ 310-320, one @ 270. OUCH! Pretty much what I expected. When the purchase of said truck was first mentioned, it was supposed to be a 2001...if I had known it was an early 99, I would rec he pass w/o even looking at it. Considering the early 99 has the smaller turbo, lower rate injectors, etc.

 

So now he either needs to rebuild or replace the engine. If we acquire a 99.5 up engine, what other parts will we need other than the later exhaust down-pipe? Intend to upgrade the air Filter to the Ford Severe Duty, so that will be handled. Since it needs a PCM, get one to match the donor engine.

 

Anything else?

 

I would consider rebuilding the engine if it were the 99.5 up. But my experience with the early 99 550 was, they were a turd when at their best.

[ktmlew]

So I guess I have it covered? Anyone have anything to add? If we rebuilt this engine and used the 99.5 injectors & HP pump would it run OK with the smaller turbo or be a huge smoke machine. I have zero experience at modding these...did find a turbo rebuild kit on ebay which includes the impellar.

[ktmlew]

Did find this interesting; http://www.dieselsite.com/index.asp?PageAction=VIEWPROD&ProdID=276

[Keith Browning]

I am not sure of the physical changes on those engines but I am thinking that changing injectors and turbo sized *might* have an effect. Remember these things are factory tuned to specific hardware, you go a changing these items and use the original calibration you are entering unknown territory. I would think some performance issues may arise. Then again, I have no experience modding these things though I feel what you want to do here is not so much a modification as it is bastardization. That could present special problems in the future as well.

[ktmlew]

I am not sure of the physical changes on those engines but I am thinking that changing injectors and turbo sized *might* have an effect. Remember these things are factory tuned to specific hardware, you go a changing these items and use the original calibration you are entering unknown territory. I would think some performance issues may arise. Then again, I have no experience modding these things though I feel what you want to do here is not so much a modification as it is bastardization. That could present special problems in the future as well.

If we go for a used engine, I will push for the newest we can find. The truck needs a PCM anyway, so using the later 01-03 PCM should take care of any calibration issues? Then he just "shops" for whatever year parts apply? The early 99 is a bastard to start with...

 

He has been driving a 92 F350 7.3 IDI Auto for 10-15 years so anything with a turbo should feel like a rocket to him.

[dieseldoc]

Although I have not done this particular thing myself yet. I would think that as long as you got a complete engine and matching pcm it should be fairly plug and play. Obviously will need some exhaust mods due to the different downpipe but nothing serious. Please let us know how it turns out I am interested in doing this very same thing but with a little bit older chassis. . . . . . . .

[Keith Browning]

Makes sense that a complete swap like that would be okay but God help the poor bastard that will need to look up parts in the future by VIN or application.

[blown99]

The ecm from the 99 is different than the 02 and ups (different number of pins/different harness). If you put in an ecm from a 99.5 and up, be sure the doner engine has the AD injectors (came in 99.5 and up engines) I know guys swap the turbos around to tailor their towing requirements etc, so just matching up a down pipe should be all that is needed for that. Some belt routing is different - two alt., upper hose goes through the belt, others go around the belt.

[Bruce Amacker]

The ecm from the 99 is different than the 02 and ups (different number of pins/different harness). If you put in an ecm from a 99.5 and up, be sure the doner engine has the AD injectors (came in 99.5 and up engines) I know guys swap the turbos around to tailor their towing requirements etc, so just matching up a down pipe should be all that is needed for that. Some belt routing is different - two alt., upper hose goes through the belt, others go around the belt.

Aren't you thinking about IH and DLC vs DLC2? I don't know of any major differences in a 99 vs 2002 PCM in a Ford 7.3.

 

I remember the 7.3 Gen 1 ('94-97) having a different pinout than a 7.3 Gen 2 (99 up).

 

Correct me if I'm wrong. I just flew in and am a bit fuzzy right now.

 

[Fredsvt]

You can plug in a '01 up PCM it'll run, but the wiring for the IMH isn't there, you'll have a permanent code stored in it for it every time it's scanned.

 

I've had to put in a couple when customers have put in Suncoast transmissions, as they want you to use the '01 PCM with a particular tear tag, as it has shift and converter strategy that they prefer to work with their units.

 

Things you'll need to put on the truck, the bigger turbo, the up pipes and inlet Y are different, as they are longer and slightly more rearward than the early '99s. The outlet manifold off the turbo needs to be replaced as the '99 is too small both where it mates to the turbo but also where it goes into the intake boxes. If I recall the intake boxes are much larger on the later motors vs the early '99.

 

I prefer the older upper hose so that you don't have to remove the damn thing to do the belt. On the newer trucks it's the hose for dual alternator trucks.

[Bruce Amacker]

You can plug in a '01 up PCM it'll run, but the wiring for the IMH isn't there, you'll have a permanent code stored in it for it every time it's scanned.

 

Isn't the intake manifold heater part of the optional "Cold Weather Package"? Maybe it doesn't have it?

 

[Brad Clayton]

The heater is for cat convertorless trucks. If the truck is equipped with a DOC then it doesn't have the heater, if does not have the DOC then it came with the heater to control white smoke.

[Bruce Amacker]

Even down south? I rarely have seen the CWP on southern trucks, and many of them don't have the EBP actuator, either. (after '99 it's an option)

 

[Brad Clayton]

Yes even down South, the smoke control became an issue with the addition of an intercooler.

[Fredsvt]

I've never seen one without the ebp system.

Sometimes I wish they didn't have it. Now that they're getting old, the damn actuator pistons are pouring oil all over when it gets cold. Makes a huge mess.

[Brad Clayton]

Only truck I have ever seen with the cold weather delete package was sold out of a Florida dealership.

[Bruce Amacker]

I had a whole fleet with no cold weather package and no EBP actuators in Texas, the same ones with no operational glow plugs. I've seen several others down south without looking hard, too.

 

I've had guys tap and cork the oil feed line in the aluminum turbo stand to disable the EBP (and it's oil leak). I'm assuming it set an OD fault (P0476?) after this "modification". Guys who popped the rod on sticking EBPs reported little or no change in warmup/heater operation after popping the rod (to disable the sticking EBP). In medium climates as ours I don't think it makes a huge difference. Maybe in Alaska or in a school bus it's a different situation.

 

[Aaron]

I've seen a few of 'em with the rod off and the butterfly jammed open up here... Coldest we see is MAYBE 0 - 10 F