Ford Superduty build.

Buliwyf

Viking with a Hammer
New guy. So bear:elkgrin: with me, I didn't see a new guy introduction forum here. I have spent alot of time with Ford Superduty work trucks, and just recently sold my Truck. My Jeep Yj isn't streetable.

So I'm looking to start a new build along the same practical camping, mild offroad, and rural highway travel alot of others here seem to embrace. I'm envious of alot of the builds here. It's nice to see tuned up trucks for a real practical purpose. Not just huge lifted show queens. (I'm ok with those, just not my style)

Hopefully I can add my experience to truck tech threads. I was a Master tech for a very short period of time before I became a generator tech many years ago.

Anyways I'm buying a Superduty this fall when prices drop as the next year models come out and fuel prices are usually high driving demand down. Not sure if I'm buying new or buying used at this point. Depends on if I can get a deal on a new truck. I can buy a fairly decent used truck for the cost of depreciation on a new one.

Lucky for me I don't need a daily driver. I have a work Van I take home that's provided by my employer. So I can make some consessions towards something a bit more aggressive than most people. Fuel economy deosnt really matter for example. I only fill my cars tank twice a month or less. Often my company vehicle can e used on my way home for most of my chores. And I allready own a small car for "boring adventureless" travel.

So onto the build plan, any advice is appreciated:

The truck -I'm starting with a Ford Superduty F250/F350. Also staying with XL model work trucks. Manual locks and windows. Nothing to fail, nothing to spaz out and lock me outside my truck on a cold day. Buying a used truck with cash is a nice idea, but given my lifestyle, a brand new truck could last me 20+ years easy.

This kind of truck is what I'll be checking out over the next three months:
New or slightly used:$27k-35k
zzzz20111FTRF3B60BEC56105-1c.jpg
:elkgrin:

Or the same type of truck used, year 2000 and up with less than 100,000 miles. These are usually around $10k in my area and often in very good shape.

Since I'm only looking at white base model work 4x4's, many of these used trucks come with torn steering wheels or seats. Who hasn't jumped into their work truck with a sharp screwdriver in thier pocket? That makes them impossible to sell to "normal people". I usually add seat covers and can replace a steering wheel easy enough. I'll most likely replace the brakes with thick Napa rotors and and if I need to, eventually rebuild the transmission. But plenty of city/county trucks see light use compared to a plow truck or daily driver. Just have to know what to look for. The tansmission appears to be the weak link of these trucks. But trans shops are getting good at repairing them.

My needs require:
-Dana 60 front axle. No 1998-2001's with Dana 50's please.
-Sterling/Visteon 10.5" rear end. Which, I imagine, becomes a 10.25 when I regear it.
-Manual hubs, manual transfer case. Old school tough.
-XL interior. Less to break, rubber floors like mud.
-No engine mods, no lifted trucks, no project truck like this. (Usually a bad sign when buying used)

If I buy new, I want the F250. I prefer it's vacuum boost brakes over the F350's hydro boost. The F350 requires less effort to stop with a trailer, but you can feel it tug on the powersteering pump when offroad or manuvering trailers in parking spots. The F250 is cheaper to insure and license as well and I only tow up to 10,000 pounds, never more.

Even though the F250's come with the smaller "5th wheel trailer height" blocks in the rear, I'll be swapping those out soon enough anyways.

Suspension:
BDS 4" would be nice, but overkill.
129_1101_01_o129_1101_flexstasy_bds_four_link_suspension_for_the_ford_super_dutyinstalled_bds_suspension.jpg


129_1101_19_o129_1101_flexstasy_bds_four_link_suspension_for_the_ford_super_dutyrti_after.jpg


129_1101_14_o129_1101_flexstasy_bds_four_link_suspension_for_the_ford_super_dutycontrol_arms.jpg


A 2" leveling kit and 305 sized tires (33") would suit my needs as well. But when you add an adjustabe track bar to get the front end perfect, the overall cost is similar to a complete 4" system. I may not add the 4 link, it's about a $500 option. But it's probally worthwhile.

[
Drivetrain:
Detroit Locker in the rear. I've never had problems with the fullcase Detroit in heavy fullsize trucks. Actually more predictable than the Ford LSD ( I shimmed it tight and used no friction modifier) I used in a previous truck. I like how these ratchet off road in turns. I don't like constantly switching off an ARB. And the Detroit works great, for me, in alot of places that it isn't wise to completely lock an axle. I love being able to gently craw through off road sections. I am not the type to use momentum often. So if that means investing in lockers, and/or stopping to put mud chains on, so be it.

Open diff up front, or if the budget allows an Ox selectable locker up front. I'd run a long Ox cable to the frame, not to the cab. Then I'd use the electric solenoid kit on the frame to actuate the ox locker. Easier, cleaner, cable run that way. A simple cheaper Detroit up front is tempting. But only if i rarely need 4wd on the street in snow. With a Detroit in the rear, my experience is that it's critical to be in 4wd when there is not pavement showing. So open or selectable is the way I need to go I think up front.

No need for fancy axle shafts. Allready running 1ton beef. I may need to a CV stle driveshaft to get rid of vibration with a short lifted truck, but that's unlikely. 4" is barely taller than stock overall.

Engine:
Stock. Fords have plenty of grunt as long as they are geared proper. 300HP is plenty.
I'm after the 6.2L or 5.4L gas engines.

I'm a hardcore diesel guy. But I have enough experience with those to know they won't suit my needs for this build. Extra weight and extra up front cost. I don't tow that often. And I usually can acheive 8-9 mpg, with a gas engine, pulling 9,000 pound generator trailers.



Recovery gear:
The Jeep had a winch. I loved it. But it's not needed with this build. I see a ton of salt/snow so a winch would be repaired more often than used. Not to mention, there is nothing within 100' of a Superduty anytime it actualy deos get stuck. At least never anything that can handle 10,000 pounds of pull.

So I better plan on not being winchable. Shovel, highlift, and wheel grabber for the high lift. I generally don't go anywhere that getting stuck isn't as simple as jacking the truck up and flopping it over, or adding dirt/rocks under the tires, or strapping on mud chains on for swampy conditions.

Mud rated V-bar tire chains are golden in mud. Not nice because they tear up the earth. Perfect for farms and flooded roads. Very cheap. Just don't use them at off road parks, they turn good trails into pits.

Lights:
No idea, maybe a pair of KC 150 watt.

Snorkle:
No. No way. Not that kind of build. I will make sure my drivetrain breathers are up high.

Other:
-Delorme GPS running on a HP mini. I had a Ram mount. It was ok. I think I'm going to use a Ram base, but fab up my own platform.
-Galaxy CB, Whip on the bed.
-bug deflector, not sure what brand
-bed liner, no ideas
-2 extra G31 batteries mounted in the bed. I'll use a manual swing switch to parallel them to the truck as needed. No fancy electronics for me, those allways fail to turn off, leaving me stranded. Chances are I'll only connect 1 of those 31's up. The other battery will just be a loose spare, worst case senerio.


Looks like I have some work to do. Later.

Buliwyf.
 
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I am starting a very similar build, see my F250 vs PW thread. I have opted for a '11 F250 6.7 diesel, factory rear locker, snow plow package, etc. Difference is a family so went with CC shorted. I have run 35s at stock height for 15k miles and no rub- live on a farm and always crossing ditches, retrieving animals, etc. I just ordered a 2.5" spacer for the front, and add a leaf in rear plus Firestone bags. I also picked up some Goodyear GSAs in 37/12.50-17. Got a great deal, so found some factory alloys in 17, painting them and overall a cheap, relatively, option. Many are skeptical it will work, but I want minimal lift and max ground clearance. Already fitted retractable steps from Amp Research in lieu of sliders. This allows more clearance and easier access for the family. Must say I have a Rover for serious trail duty, but this truck is the do-it-all travel rig and dd. Short on time right now, but love your logic and approach as it is very practical- best of luck!! And I might add, find a good dealer(have a uncle with a dealership if that helps), get a lightly used '11 from the Ford sale, and for $400 get it CPOd for tons of cheap additional warranty, save the depreciation, cheap finance rate if needed, nd still have basically a new truck. For the record, the 6.2 is way strong, but thirsty. The new diesel is amazing in all regards except initial cost, 400hp, 800# torque, and a real 20+ mpg, even getting over 15 towing 8-9k... Best of luck, and welcome aboard!!
 
Thanks.

I agree minimum lift is the way to go. If, in the future I need 38" tires I'll cut the fenders. I'm not going taller than a 4" lift.

I have spotted a 250XL with a factory locker installed. I thought that was an odd combo. Not too many working style trucks with features like that.
 
Finally I have had some time to spin wrenches. I know some folks are wondering exactly how easy Ford Superduty brakes are to do yourself. So I made a tutorial. It's really easy.

First you have to remove those terrible tripping boards:
DSC02607.jpg


You'll need these tools exactly:
DSC02602.jpg


My front wheels came off easy. Then squish the pad into the caliper to press the caliper piston back in, two clamps are better than one. You can't use a prybar or anything to push on the caliper, only a big clamp works.
DSC02588.jpg


Undo the caliper bolts. Oh, oh. caliper is stuck can't get it off:
DSC02589.jpg


No problem, turn the wheel and pull the large brake cage bolts to remove the whole assembly:
DSC02591.jpg


Rotor pulled right off. All disassembled:
DSC02592.jpg


Allways use new slide pins. Many brake systems have failed due to old stinky pins being bent and binding up the caliper or damageing the caliper by bending it as well. One of my rear calipers failed because the idiot that did the brakes for this trucks previous owner messed up one of the pins and damaged a caliper and rotor:
DSC02594.jpg

coat those pins with anti sieze. A good high temp grease. Copper or Silver is fine.


Hose down the rotors:
DSC02593.jpg


Use blue threadlock on the large cage bolts:
DSC02595.jpg


Bolt the cage on and install new pads and springy things. Make sure pads can slide and that springy things can bring them back:
DSC02597.jpg


Use the old pads to press the pistons back into the caliper:
DSC02598.jpg


Put the caliper back on:
DSC02601.jpg


The caliper should slide back and forth easy. A little more than 1/8".

The cage bolts can be torqued to whatever a man with a breaker bar can put out. I used a pipe on my breaker bar.

The caliper bolts are weaker. Which is why I allways replace those bolts and pins. You can feel the threads stretch around 100 ft/pounds. Don't overtighten them.


The fool that owned this truck prior to me just had these brakes done. The pads were new. They pad slapped it. Why would someone pad slap a truck with 100,000 miles+? These brakes felt terrible, warped rotors, sticky calipers. Poor attention to detail. That ASE mechanic is lucky he didn't kill anyone.
 
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So that's the fronts. But the truck still shakes like it has a warped rotor. And now that I know that this trucks previous owner/mechanic was completely incompetant. I better do the rears.

Getting the rear wheel off was a bear. From now on I'm keeping my large hammer in the back of my truck incase I get a rear flat. With my Chevy's I can loosen the lugs, drive forward, hit the brakes to break the wheel loose. That didn't do jack to this monster. A few good hits, then spin the wheel 90 degrees and give it a few more, then spin. By the time you get all the way around it should be loose. Don't hit just one side of the wheel.

If your rotor looks wavy like this:
DSC02663.jpg

Then your caliper is shot. In my case one of my brake pins was installed wrong. One of it's edges was smashed. I think the pin was bent due to this, which bound up the caliper, which destroyed the rotor. Wost mechanic ever! Some people should never do brakes.

You can expect your rear rotors to be siezed onto your hubs. Spray some penetrating oil on them. No amount of hammering on them will get them off. You're just hurting your truck with a hammer and completely wasteing your time. This ain't no little Honda.

I considered using this camshaft to beat them off.......but I couldn't even pick it up:
DSC02647.jpg


This is the proper rotor pushing method:
DSC02654.jpg

Use a bolt and nut in the cage mounting hole to push the rotor off. Tighten the bolt and it pushes on the rotor. Don't put too much torque on that bolt. You don't want to hurt your hub or bearing or bend the axle.

Tighten then loosen, then spin the rotor 90 degrees, tighten then loosen, so on, and so on until the rotor snaps free. Then just wobble it with your, by now, quite bloody hands

DSC02661.jpg

I had to replace the entire caliper on the rear drivers side. When I reinstalled the old cooked caliper, it would bind up and not slide free. With loose caliper bolts it slid fine. I blame the damaged pin.

I used only the hand tools shown, and a piece of pipe. I used the spare tire jack. Why? Because this trucks new to me, I wanted to make sure I could use the spare jack and lug wrench. I used some jack stands for extra safety. But I avoided being under the truck for all of this.

I hand tighten the wheel lug nuts. 80, then 100, then 150-165ish. No air tools needed for brakes. Not like they fit in there anyways. Getting brake dust blown in your kinda face stinks as well.
 
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wow what a great build you have going. The one thing i wish is that i went with a 4inch lift like you are planning instead of the 6" lift. But it seems up here in alberta if you don't have a big rig rocket diesel your not cool enough haha. Great build.
 
Good start. I also found that 4" lift with 35s is a happy medium for daily driver and off road duties. I have some of the same brake issues as you up front. Calipers binding. Need new slide pins. Just put new rotors and pads on it and didn't do the pins, Now I gotta tear it down again... Pays not to go cheep.
 
Just got back from my trip to Florida towing a trailer to my home in Ohio. So now I can start the mods.
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Minor setback: A Suzuki DRZ400S made it's way into my stable as an "ExpeditionPortal Bike". Setting my F350 budget back a little ($6000 back with $1000 in farkels).
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I've got the WetOkole seat covers on. Airlift rear Airsprings with Internal Jounce bumpers installed. New starter, battery, and fan clutch. New Carpet. Picked up some folding bike ramps.
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Also since the truck is doing awesome offroad in stock form, I may go a little conservative with my build.
Likely:
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Carli 2" Leveling Kit
Bilstein 5100 shocks
4" F350 rear blocks
Detroit Locker with stock 4.10 gears
285/75 17 Cooper STT Mud terrain tires
Back rack with lights angle mounted to illuminate the corners of dark sharp turns.
XLT headlights
Powdercoat Front bumper black
2011 Side Mirrors
Monstaliner the bed (this fall)
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Allthough the BDS 4" Lift is still on my mind. I'll have to get some quotes locally and get ideas if 315's will clear my Airlift airbags. So far my trucks mileage is marginal and acceptable. 315's might not be the wisest idea.
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Computer stand goes in, next month, with my repaired Galaxy Dx55 with the bedrail mounted antenna. Picked up a used Dell computer for only $80.
 
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Finally got some time to wrench.
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Painted my wheels Expo black. Scuffed, sprayed sandable buildable primer, then sprayed VHT Epoxy gloss black from a distance for a matte gloos black look.

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Upgraded to the XLT style headlights. I had to cut the sealed beam harness and solder on new plugs. I used an Ebay light housing clear lense but with black plastic. matches up with the black grill way better than the chrome plastic headlights.

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Installed a Ram computer stand. I think the stand for 05-06 Superduties was better and more solid than this one. They likely fit just as well. I'm going to run Delorme Streets and Trips GPS on it.

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Buyers (made in Mentor OH) pintle ball hitch. 14" shank to keep the trailer away for tighter maneuverability. 12" of lift. 4" drop. Running it upside down is also possible on smooth roads.

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Random pics:

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lights need adjusted up, grass needs mowed
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I think the black wheels look tough
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Next week I'm pulling the nice straight but ugly front bumper and sanding and painting it to match the wheels. Same with the rear. Actually going to bondo a couple dents in the rear bumper first.
 
Back rack with lights angle mounted to illuminate the corners of dark sharp turns.
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Allthough the BDS 4" Lift is still on my mind. I'll have to get some quotes locally and get ideas if 315's will clear my Airlift airbags. So far my trucks mileage is marginal and acceptable. 315's might not be the wisest idea.
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I like the idea of the angled lights.
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Now the bigger tires, that all depends on where you want to be able to go. I'm glad I went with a taller tire, but my truck is 14 years old, and I take it many places somebody with a new truck won't go. I do pay for it at the pump, it's just that for me, it was worth it.
 
Allmost forgot. I added rear airbags so the truck stays nice and level and stiff with a camper in the bed or a huge trailer. I chose the Airlift kit that mounts over the springs. As far out as possible offers the most roll stiffness. and these have the internal jounce bumpers so can be run with 0psi safely. Cool thing about the internal jounce bumper, it takes up a ton of internal space, so when the bag is squeezed, pressre ramps up quicker than an empty bag. That's why you can safely run them empty, and they have an excellent progressive spring feel.
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They reduced the porpoising of a loaded truck and trailer completely. The ride did smooth out with added pressure. with the bed loaded with a trailer on the way home from Florida I needed 70 psi in them. Towing a tandem dually flatbed trailer with a Bobcat (about 10,000 pounds, or at least that's all I'm going to admit to until the whole statute of limitations thing runs out) on the back only required 30psi.
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Install pics are self explanatory:

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Centerpunch to drill bolt hole.

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Wind pressure coming off the front of the trailer tried to make my bed liner fly away. Will be using Monstaliner soon.

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Can't wait to get rid of the junkyard 2001 mirrors for some fresh 2012 mirrors

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Apparently my truck and that trailer have a perfect alignment. 2 finger steering all the way down 77. (not me driving)

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We put all the steel in the bed to keep from overloading the trailer

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I like the idea of the angled lights.
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Now the bigger tires, that all depends on where you want to be able to go. I'm glad I went with a taller tire, but my truck is 14 years old, and I take it many places somebody with a new truck won't go. I do pay for it at the pump, it's just that for me, it was worth it.

Yeah. The Backracks have a nice tab accessory so you can mount lights at the top rear corners of your cab. great for aluminating the sides of the trail. Or with a quick spin, they're nice backup lights.
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I'm think I might try the Cooper STT 295/75 r17 tires. By my ruler, they should clear my airbags easy. I only drive this truck on weekends. It's literally a travel/camping truck. So mileage isn't a huge obstacle. But I do use it every weekend.
 
Mine is a every day driver, so I have to build it for everything I want to do... Just now I'm working on storage cabinets in the back for camping... pardon me, Expo travel.
 
Can't wait to get rid of the junkyard 2001 mirrors for some fresh 2012 mirrors

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I bought a set 0f 08 and up towing mirrors on ebay for a great price. the are knockoffs and manuallly fold in and extend, but are power adj, with light, and heat. they bolted right up in about 10 min and took about an hour to tie in the lights.
 

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