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Indeed. Nice running into you and Evil Tracy Sat in Sedona.

What I have learned while doing a FF D60 rear axle swap on my SMB is that there is no paint-by-numbers guide available. Ujoint offers an awesome DIY kit if you source the axles either from him or find them, as he recommends, from a 99-04 F-series or Excursion. Otherwise, be prepared to do your...

The Bulletproof oil cooler is a solution in search of a problem IMO if the other stuff has been taken care of. I presume the tune that turns off the EGR valve is really only to turn off the check engine light since the EGR cooler has been deleted. Awesome rig.

The stock oil cooler is actually quite functional if the Ford Gold coolant has been properly maintained. Monitor the temp spread between EOT and ECT and if the spread get's bigger than 14 or 15 F then you have a problem. An external oil cooler like the Bulletproof version is quite expensive...

No worries, and it wasn't my intent to bag on the powermax. But you may experience some turbo lag. If you don't already have one, consider an SCT tuner and getting a custom tune for it. KCturbo has a billet wheel as well as Riffraff and Dieselsite. I'm really like the one in mine. Single...

Chris's pic makes the vans on the right almost as big as Earth Roamers:Wow1: As for the vents, I think 11x17 is the size I'm going to go with on my 2005 E350. http://www.hoodlouvers.com/product-category/size-large-hood-louvershood-vents/

As I understand it, it's a tracking issue. In a turn the rear wheels roll in a smaller arc. It put's less stress on the drivetrain and makes turning easier. I would think it would be even more exacerbated with a Detroit Locker.

I think the upgrade part 3C3Z9T516A is for the 2003 - 2006 model years, but you can tell if you have the old one if it has the flex housing. The jury seems mixed on whether the new one is really an upgrade part for the expense but most agree that the new unrestrictive drain tube 6C3Z9T515A is a...

Yes, it will work. But unless you are going to do the rebuild yourself I would just buy a drop-in replacement. Labor is $600 or so to completely clean it and another $200 for rebuild parts. If you are going to do that I would install a 360 thrust bearing rebuild kit and a billet compressor...

It's a good thing as that is how they are lubricated. But it appears you have a semi-floating axle so it's not quite the same issue (ie., one set of bearings and not an inner and outer in a full float hub). I guess that's how the inner bearings can potentially burn out on a full floater is...

I presume the articulation test was also to get differential fluid to the inner bearings? That is, I presume you put the axle back together dry or did you pack the bearings with grease? As I understand it if you pack the outer with grease it might block the diff fluid from getting to the inner...

Since you are planning an mtb assault vehicle have you given thought to how you are going to carry your bikes? I find that 4 off the back is a bit much. I got tired of having to dance around a hitch rack to access the back of the van. I even sprained my knee once while doing a twist and turn...

Dang, not that close. At least 20 miles to the east. Similar rocks though. I cut my teeth on a geology M.S. degree on the Triassic Chinle Formation. Anyhow, nice rig:26_7_2:

Having been agonizing over axles and all the permutations lately (props also to Ujoint for answering many emails) I'm not sure why you think you need spacers? It doesn't sound like you picked up a 4x4 so the rear should already be the same trac width as the front, no? Simple is right in that...

Since I like to play the location in the pic game I will venture a guess that Eric's testimonial pic is just below Pucker Pass in Long Canyon, Island in the Sky, Canyonlands?

climb up the ladder. Pretty handy item if you have a roof rack. http://www.aluminess.com/ford/ford-vans-1992-2007/ladders/

ball joint info I posted this in a ball joint thread on the SMB forum after spending way too much time on researching ball joints. If you only want to do it once the King is the rebuildable Dynatrac. If you ever have to rebuild them at all but it's not uncommon for a 10,000 lb to go through 2...

Pulling the body takes on new meaning if it's been subject to a camper conversion. Cargo van yes but seems like pulling the engine is the easier option. Either way, stuffing a diesel in there doesn't leave much room. If you don't do your own work it really pays to find someone who actually...

Nice write-up and awesome build thread. I'm doing the same thing on my 6.0 at 90,000 miles with the same delete kit. It's all going back together so hope it starts. I also replaced the water pump since it was right there. Good thing, as mine had a broken impeller blade. The Ford gold coolant...

The Sherpa is badA$$!