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F350 Build and Motor Swap

Old 04-28-2016, 10:14 AM
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Default F350 Build and Motor Swap

I had this posted in another forum but since we have a few ford guys here I figured I would post it here as well, some of it is a copy and paste.

Some background info, little lengthy

Sold my f250 gasser wanting to find a crew cab diesel ford. I'm not sold yet on a newer one (6.7 without deleting), and wouldn't buy a 6.4. Came down to a 2005-2007 6.0 or a 99-03 7.3. Figured why not buy a 7.3 due to how simple and reliable they are and I plan on running this truck for a long time, want to drive it past 400k.
Being in the northeast its not easy to find a clean almost rust free truck. Most of the trucks I looked at had rust on them and would have needed an oil pan at some point (known to rust) and that requires pulling the motor.
While I was looking for a truck my friend wrecked his f250 which happen to be a 7.3, and just after that I came across a clean f350 with a bad motor. Decided to buy both and do a swap along with updating a bunch of parts while the motor is out.
The truck is a 2000 F350 SRW Crew Cab Short Bed with 248k. Its an XLT with gray cloth interior. 5 seater with console in the middle. 7.3 and auto. The miles on the truck don't really matter to me as I will be replacing most of the parts on the truck with new anyways.

Originally I was only looking at lariats, but with this being a unique situation the xlt was fine as I am putting a new interior in it. It had all the other options I was looking for such as the off road package with skid plates and rear limited slip, and a dual alternator setup from the factory.

Both motors were pulled last night along with the trans in the donor truck. The donor truck is a zf6 manual so I wont be using that trans but took it out to sell it.

Feel free to add input on the mods, will add more later as I think of it.

I do a good amount of driving, 20-35k a year and want to make the truck perfect and as comfortable as possible.
The goal is to make I ride as nice and as quiet as a new truck.

"To Do" List while motor is out

8 new glow plugs (Motorcraft)
New O-Rings on each injector (Alliant)
manifold bolts (Ford oem)
manifold gaskets (Felpro)
turbo pedestal o rings (Ford oem)
up pipe gaskets (Felpro)
Already has a new waterpump, starter and Glow plug realy
Oil pan is in great shape but weeping at the gasket as someone had replaced it at some point but didn't seal it properly, pan will be removed, sanded and painted and re installed


"To Do" List - Fun Stuff,

Pro Comp 22210 Level up front---May leave stock for now as the tires don't rub at all with the v code front spring
Zone offroad adj track bar---Will leave stuck until level
315/75/16 bfg ta ko2 (already have)
16x8 raceline octane wheels (already have)
2005 front end
Remove chrome fender trim and add oem style color matched (silver) trim
Color matched door handles
20 inch led bar in fog light opening
40 watt led flood cubes in Backrack
Backrack with modified toolbox brackets
Weatherguard 123-5-01 extra deep black saddle tool box
Viar 444c onboard air with 2.5 gallon tank
katzkin full gray leather with heated seats---or lariat interior swap if I can find a donor truck or someone parting one out
sound deaden entire cab floor, doors and roof
New carpet with extra thick backing
Possibly add overhead dispay and temp readout
Sherwood 5pc dash kit---If I do not do the lariat interior swap
Double din radio with backup camera
Custom upfitter switches or F650 lower dash
Remove visor and add amber cab lights
amber chicken lights down sides under doors
2005 or 2008 tow mirrors with ambers in them
Light tint on front windows and rear window


"To Do" List - Engine and upgrades

TS 6 Position with custom tunes
6.0 trans cooler
Hutch and Harpoon mods with pre pump screw on filter/ water separator
6637 intake
all the known upgrade mods
Bilstein shocks
Either triple or quad pillar gauges

Last edited by jlipsky14; 04-28-2016 at 10:43 AM.
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Old 04-28-2016, 10:18 AM
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New truck is a white 2000 F350 SRW Crew Cab Short Bed

Donor truck 1999 F250 Extended Cab Long Bed
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Old 04-28-2016, 10:22 AM
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Got my shipment in from riffraff diesel that I had been waiting for with the new manifold bolts, uppipe bolts, turbo pedestal o rings and uppipe donut gaskets.
Ended up getting out of the garage just before 3am. Got the manifolds off, I had to cut each bolt just behind the manifold leaving an inch or so to grab onto. I wasn't able to get a grinder or cutoff wheel behind the manifold so I ended up using the hackzall. Went out and bought Milwaukee torch blades they were the best I could find. Pretty much went through one blade per bolt. Tried a diablo metal blade and it didn't last 20 seconds before there were no teeth left on it. Was able to spin out 14 of the 16 bolts with a vise grip. One bolt broke off leaving about 1/4 of an inch sticking out and the other wouldn't budge and broke a usa made vise grip in the process. Will try to weld nuts to both of these and back them out.
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Oil pan was also removed scuffed and the first coat of por 15 was applied, will do a few more on it. May end up just doing a new oil pan just cause but this one is in pretty good shape.

To do list for today:
Clean surface and bolt on manifolds with new gasket
Remove old bolts that are rusted into the uppipe clamps and reinstall
Install new glow plugs
Install new injector o rings
Install Oil Pan after a few more coats of por 15

I am hoping to get the motor in either tonight or tomorrow night.
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Old 04-28-2016, 10:24 AM
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Have gotten most of the bugs worked out but still have a starter issue to figure out then will be moving forward with the rest of the items.
What I have done since the last update:
-replaced idm, was killing whole passenger bank of injectors
-installed new db electric high torque starter
-Replaced neutral indicator switch which was making it hard to shift
-energy suspension front sway bar and end link bushings, painted sway bar and end links.
-modified header panel and installed 05-07 headlights
-got the rear bumper on
-Sold the stock wheels/tires and got my bfg ta ko2s on
-temporary Monroe shocks that were almost new from the donor truck, painted silver metallic
-all calipers removed greased, inspected, and painted some were swapped out with better calipers until I buy all new ones
-installed the double din with backup cam, ended up with a cheaper boss audio as im not big into audio and all I really wanted was a backup camera, already had stock speakers replaced with kenwoods
-installed the mile marker 449ss locking hubs
-new brake lines on rear axle after I popped both originals before even leaving the driveway

Here she is as of this morning, got the backrack in the mail today with the new low profile toolbox brackets.
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Old 04-28-2016, 10:29 AM
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Didn't see a tuner on that list? Did I miss it? The 7.3 is a great motor but I gotta have a lot more throttle response in my daily driver.

Is there any way to up the mpg on them? That's the other place they suffer.

You should be able to go waaaay past 400k on that thing when you're finished.
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Old 04-28-2016, 10:34 AM
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Yes its on the list , bottom of the first post.
I have a TS 6 from the donor truck that I will have reflashed by PHP, will probably leave it on a 65hp daily tune most of the time.
Not sure on the fuel mileage but that will definitely be taken into consideration with the tunes. Anything will be better than the 5.4 I used to have and I just paid less yesterday for diesel credit than regular credit would have been
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Old 04-28-2016, 10:39 AM
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I thought about doing something like this but with a 80's model f-350 srw 4X4 and a 6.7L Cummins.
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Old 04-28-2016, 10:53 AM
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Originally Posted by 1fast6 View Post
I thought about doing something like this but with a 80's model f-350 srw 4X4 and a 6.7L Cummins.
This one was a fairly easy swap, most of the trucks I looked at before this one would have needed an oil pan at some point anyways which means the motor would have to be pulled anyways. So I figured what's the difference if I take the engien out and put it in another truck vs putting it back in the same one
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Old 04-28-2016, 01:31 PM
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I would get the dorman bellowed up pipe kit its a nice get I have used several of them it gets rid of the stock donut gaskets that leak.

When you reseal the oil pan use motor craft gray sealant it works the best as there is no pan gasket and the surface must be clean really well to get a tight seal.
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Old 04-28-2016, 01:49 PM
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Originally Posted by jlipsky14 View Post
Yes its on the list , bottom of the first post.
I have a TS 6 from the donor truck that I will have reflashed by PHP, will probably leave it on a 65hp daily tune most of the time.
Not sure on the fuel mileage but that will definitely be taken into consideration with the tunes. Anything will be better than the 5.4 I used to have and I just paid less yesterday for diesel credit than regular credit would have been
Yeah, same here this morning. Paid $1.72 for diesel and reg unlead w/ ethanol was $1.99 at the same pump.

4 friends had/have 7.3 trucks / Excursions. They seem to average about 14 mpg city and hwy. One guy with an Excursion he uses to pull his 31 Bert has north of 350k miles now and it still runs great. My cousin also has a 4x4 Excursion but has recently (last couple of weeks) had to park it / replace it because his oil pressure was so low it wouldn't start cold - something about oil pressure and injectors. He has right at 350k miles too. Mechanic blamed it on the POS K&N air filter he's been running since the truck was new. He's planning to rebuild the motor and trans (which has also been giving him trouble lately) and drive it some more...

Great motors.
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Old 04-28-2016, 01:52 PM
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Already did the oil pan gasket and I did use the motorcraft gray sealant, I also put an extra coat of Por-15 on the oil pan before I installed it to make sure I don't have a rusting issue down the road.

The motor that I put in the truck was from an Early 99, so I only have two option for up pipes. One is the riffraff diesel bellowed set at $500 or the International ones for $900.
The ones that were on it looked really good and had not been leaking, they may had actually been replaced already. I cleaned all mating surfaces, bought all new hardware and got the new slightly larger donut gaskets.

If I ever have to do them I will probably convert the motor from an E99 to L99, I am going to have the injectors that were in the 2000 rebuilt (rosewood diesel) and I saved the turbo, turbo pedestal and all engine parts from the 2000.


If anyone needs anything for these trucks talk to Clay at Riffraff diesel, IMHO they are the best out there. I was always able to get Clay on the phone even to ask him a question about my swap that didn't have to do with an order. They have the best prices I have found on both aftermarket and Ford Motorcraft parts.
Also for injectors talk to Jim at Rosewood diesel, super nice guy an answered all the questions I could ask and was more than willing to help me out any way he could.
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