This Ford was Torn Down to the Frame—and Improved Step By Step
Mark Vanadia –
Jun 1, 2012
Photo 1/38 | total Rebuild 2006 Ford F350 completed 2006 Ford F350 | 35. Here the truck is complete on August 4—on its way out to Carlisle All-Truck Nationals.
Photo 2/38 | total Rebuild 2006 Ford F350 2006 Ford F350 Mark Vanadia Rebuild | 01. This is Mark Vanadia’s ’06 F-350 Lariat 6.0L Power Stroke extended-cab shortbed pickup truck as it sat before the rebuild. The truck has a 10-inch Donahoe Racing suspension lift with Pro Comp traction bars, a Donahoe dual steering stabilizer setup, Kumho 38x14.00 Road Venture mud terrains, and 24x11 black Fuel Hostage wheels. As it sits in this picture, the truck also has blown head gaskets.
Photo 3/38 | total Rebuild 2006 Ford F350 stock Wheels Added | 02. Here is the Ford after we added a set of stock wheels on 33s, which made it easier to maneuver the truck as well as give less concern for scratching the 24s.
Photo 4/38 | total Rebuild 2006 Ford F350 drain All Fluids And Remove Grille | Total Rebuild: 2006 Ford F-350
Photo 5/38 | total Rebuild 2006 Ford F350 unbolt Motor Mounts | Total Rebuild: 2006 Ford F-350
Photo 6/38 | total Rebuild 2006 Ford F350 motor Removed From Truck | Total Rebuild: 2006 Ford F-350
Photo 7/38 | total Rebuild 2006 Ford F350 set The Motor On Blocks | 06. Once the motor was pulled out, we set it down on blocks, making sure it was steady and solid to start tearing the top end down.
Photo 8/38 | total Rebuild 2006 Ford F350 remove The Alternator | 07. Starting from the top end of the motor, we removed the alternator, turbo, wiring harnesses, heat shields, oil cooler, intake manifold, and EGR cooler before we got to the heads. Once we pulled the heads off this truck, this is what we found. There was about 1/2 cup of coolant in five of the eight cylinders.
Photo 9/38 | total Rebuild 2006 Ford F350 motor Torn Down To The Block | 08. Here’s the motor torn down to the block. The heads were sent to the machine shop to get checked for cracks and then milled down flat. The shop had to take minimal amounts off each side to get them flat, and fortunately, there were no cracks. We also sent the injectors out to Jesse at Warren Diesel, who bench-tested them and rebuilt them into 205s with 100-percent nozzles. While waiting for those parts to come back, we cleaned the motor and added some items to the “to do” list.
Photo 10/38 | total Rebuild 2006 Ford F350 ready To Paint At Dons Detailing | 09. With most of the body parts removed, now was the best time to paint it. Here we are at Don’s Detailing, where we pulled the cab from the truck and prepped the frame for paint.
Photo 11/38 | total Rebuild 2006 Ford F350 install Egr Delete | 10. Part of the rebuild was to fix some issues in the motor. In order to make the truck reliable, an EGR delete was put in, as well as an oil cooler rebuild. This is the oil cooler after we took it off the motor.
Photo 12/38 | total Rebuild 2006 Ford F350 filter Housing Removed | 11. With a few cans of brake cleaner and a rebuild kit from Ford for the oil cooler, we went to work. Here we have the filter housing taken off the top, as well as the cooler pulled from the motor of the oil cooler housing. Next, we replaced all the gaskets and O-rings that came with the kit, installed the new cooler, and put everything back together.
Photo 13/38 | total Rebuild 2006 Ford F350 install Clean Oil Cooler | 12. A nice, clean oil cooler ready to be put back on the motor.
Photo 14/38 | total Rebuild 2006 Ford F350 being Putting Motor Back Together | Total Rebuild: 2006 Ford F-350
Photo 15/38 | total Rebuild 2006 Ford F350 injectors Overview | 14. The injectors in all their glory.
Photo 16/38 | total Rebuild 2006 Ford F350 upgrade The Bellows | 15. We upgraded the bellows on the up-pipe in order to prevent future leaks. Here you see Louis welding them into place.
Photo 17/38 | total Rebuild 2006 Ford F350 bellows Comparison | 16. You can see the difference in the new stainless bellows versus the stock ones sitting on top of the pipe.
Photo 18/38 | total Rebuild 2006 Ford F350 completed Motor | 17. After many long nights, the motor was finally 100 percent back together and ready to be put into the truck.
Photo 19/38 | total Rebuild 2006 Ford F350 painted Frame By Dons Detailing | 18. After patiently waiting, we got down to Don’s Detailing and saw the painted frame. We opted to go with a coat of POR 15 to protect the frame from rust and added a shot of gloss black on top.
Photo 20/38 | total Rebuild 2006 Ford F350 front End Of The Frame | 19. Here’s a look at the front end of the frame.
Photo 21/38 | total Rebuild 2006 Ford F350 install Suncoast Torque Converter | Total Rebuild: 2006 Ford F-350
Photo 22/38 | total Rebuild 2006 Ford F350 bolt Everything Down For Cab Replacement | 21. Once we got the powerplant back into the frame, we bolted everything back down and got the frame ready for the cab to be dropped back into place.
Photo 23/38 | total Rebuild 2006 Ford F350 lift Back Of The Frame | 22. With the use of two forklifts and some very careful maneuvering, we were able to lift the back of the frame and roll it into place underneath.
Photo 24/38 | total Rebuild 2006 Ford F350 lower The Cab Carefully And Evenly | 23. The cab was lowered very carefully and evenly, making sure there were no binds. We checked everything for clearance as we went.
Photo 25/38 | total Rebuild 2006 Ford F350 load Truck Onto Tow Truck | Total Rebuild: 2006 Ford F-350
Photo 26/38 | total Rebuild 2006 Ford F350 install Airdog 2 Fuel System | Total Rebuild: 2006 Ford F-350
Photo 27/38 | total Rebuild 2006 Ford F350 install Mbrp Exhaust | 26. We installed the 5-inch turbo-back MBRP stainless exhaust.
Photo 28/38 | total Rebuild 2006 Ford F350 2006 Ford F350 Without Essential Parts | 27. With all the excitement of the truck turning over, we were very eager to get it done and take it for a ride. But we still had to install the intercooler, boost tubes, radiator, A/C condenser, trans cooler, linkage to the transmission, radiator support, and all the lines.
Photo 29/38 | total Rebuild 2006 Ford F350 header Panel In Place | 28. With our deadline of August 1 quickly approaching and Truck Nationals only a few days after that, we were starting to near the end of the build. With the front header panel back in place, the front bumper back on, and the foglights wired up with new HIDs, the Ford was almost done.
Photo 30/38 | total Rebuild 2006 Ford F350 wheelwells Back In Place | 29. We put the wheelwells back in place and reinstalled the fenders.
Photo 31/38 | total Rebuild 2006 Ford F350 finalized Engine Compartment | 30. After finalizing the engine compartment, the new hood went on.
Photo 32/38 | total Rebuild 2006 Ford F350 new Hids Installed | 31. The last few touches on the front end included the headlights and grille, which also had new HIDs installed.
Photo 33/38 | total Rebuild 2006 Ford F350 removed Green Lights In Cab | 32. We removed every green light bulb/LED in the cab of the truck (window switches, lock buttons, dash accessories, steering wheel controls, A/C unit, and headlight switches) and installed red LEDs. This was a unique idea that really adds to the detail of the cab of the truck. These LEDs work fantastically with the GlowShift gauges and the customizable Edge CTS monitor.
Photo 34/38 | total Rebuild 2006 Ford F350 truck Bed Reinstalled | 33. We put the bed back on the truck and installed the ’11 tailgate with step and backup camera, as well as a new Pioneer navigation unit in the cab.
Photo 35/38 | total Rebuild 2006 Ford F350 final Touches To 2006 Ford F350 | 34. The final touches included putting the 38s back on the truck, installing the methanol injection system, loading the custom tuning, and clamping down the new 6-inch stainless tip to the exhaust.
Photo 36/38 | total Rebuild 2006 Ford F350 completed 2006 Ford F350 | 35. Here the truck is complete on August 4—on its way out to Carlisle All-Truck Nationals.
Photo 37/38 | total Rebuild 2006 Ford F350 red Gauges Installed | 36. The red gauges look awesome.
Photo 38/38 | total Rebuild 2006 Ford F350 2006 Ford F350 Rebuilders | 37. The truck did, in fact, make it to the Carlisle All-Truck Nationals. Left to right: Louis Amaducci, Mark Vanadia, Anthony Contino, and Justin Herold. Not pictured here is Nick Schirripa. Mark and his four friends built this truck in six weeks, and up until 10:30 the night before they were leaving for the All-Truck Nationals, they were still trying to get the methanol injection hooked up. There were a lot of late nights in the garage for this crew. Mark also wants to thank Xtreme Diesel Performance for helping set up many of the parts in this build.