Goin’ for Broke

A Budget-Built, 600hp 7.3L Puller

Making the most of any situation is what life’s all about. For Zach Green, that meant converting his once daily-driven ’02 F-250 into a dedicated sled puller. After a wreck on black ice landed the truck on its roof back in 2012, his insurance company considered it a total loss. He didn’t feel the same way—as even though the truck had rolled, the damage was minimal. After a little time with a porta-power and a windshield replacement, evidence that it’d been upside down was virtually nonexistent. Still, the ’02 F-250 could no longer be registered in Green’s home state of South Carolina, forcing him to improvise. It was here that the “Goin’ for Broke” idea was born: a budget-built 7.3L that could mix things up on the local Carolina Truck and Tractor Pullers circuit.

Long Block Swap

With a powdered metal rod version of the 7.3L Power Stroke under the hood, Green knew it would never survive the kind of power he wanted to make. After hunting down a cheap ’97 long block—an engine equipped with forged-steel rods—he resealed the oil pan and lowered it into the truck. The few hard part upgrades the 7.3L did receive were a set of Stage 2 beehive valve springs from Swamp’s Diesel, Smith Brothers pushrods, and ARP head studs.

300/400 Hybrids, Gen3 HPOP

Jumping right in, Green opted for a set of 300/400 hybrid injectors from Performance Injection Systems, along with all the supporting mods required to keep them happy. Adequate high-pressure oil volume is on tap thanks to a Gen3 pump from Swamp’s Diesel (coupled with a factory 17-degree unit). Sufficient fuel supply makes it to the injectors courtesy of Irate Diesel Performance’s basic competition system, which works in conjunction with a regulated return setup from Diesel Innovations. The dual tasks of taming the 400% over nozzles and keeping the connecting rods straight was left in the hands of Power Hungry Performance in the form of custom PCM tuning.

2.5-inch S400

As if competing with the HEUI injection system isn’t enough of a challenge, Green’s local pulling class dictates that he can only run a map groove style turbocharger if its inducer size is 63.5mm (2.5 inches)—which is miniscule when it comes to feeding 7.3 liters of displacement. To make the most of the situation, Green reached out to a company on the leading edge of aftermarket turbo technology: Engineered Diesel. The call was answered with a competition-ready, billet 2.5 charger that produces just shy of 60 psi of boost. It mounts at the back of the lifter valley thanks to a complete T4 turbo mounting kit from Irate Diesel Performance.

Fortified 4R100

Keeping the transmission build local, Green had nearby Stone’s Performance prep the truck’s four-speed automatic for sled pulling. Things get started with a 4-disc DPC converter sitting on a billet input shaft, Alto Red clutches provide minimal torque loss from the converter to the output shaft, and valve body and pump mods keep pressure up. To manually control gear changes and lockup, Green uses a shift box built by 7.3L guru Matt Maier.

A Content Underdog

As you might’ve guessed, Green’s Super Duty is never the favorite when it rolls into the fairgrounds. But he has nothing to lose. His HEUI-injected, stock-bottom-end 7.3L is up against a sea of built-to-the-hilt Cummins and Duramax mills, many of which are cranking out 400 more horsepower. The fact that his Ford can hold its own against some of the strongest running trucks in the Southeast says a lot about its overall setup and his driving experience. With more than 130 hooks on a junkyard 7.3L that regularly sees 4,200 rpm and nearly 60 psi of boost, it’s easy to see why the weight box says Goin’ for Broke. DW

FREQUENTLY ASKED QUESTIONS

How can rust and sludge formation affect a diesel engine?

How Rust and Sludge Formation Affect Diesel Engines

Diesel engines, like all mechanical systems with frictional components, are vulnerable to the damaging effects of rust and sludge, especially after long periods of inactivity. Let’s break down how these factors specifically impact engine performance and longevity.

The Role and Degradation of Engine Oil

Engine oil is crucial for reducing friction and wear among moving parts. Over time, even without use, engine oil can lose its viscosity and fail to create the protective film required for smooth operation. When this occurs, critical components like shell bearings, piston rings, and turbocharger bearings can suffer significant damage due to insufficient lubrication.

Sludge Formation from Diesel Fuel

Diesel fuel is inherently “dirty,” containing impurities that can penetrate filters designed to capture particles as small as 5 microns. While the engine is running, these particles generally flow through the system without causing immediate harm. However, when an engine remains idle, these particles can settle and form sludge. This sludge obstructs fuel pathways and can severely damage sensitive parts of the injection system, compromising engine performance.

The Menace of Rust

Rust is often referred to as the “enemy” of machinery. When diesel engines are left unused, their iron components are prone to rust, especially in humid environments. Rust not only weakens these components but can also lead to deterioration, affecting the engine’s structural integrity. The resultant damage can reduce efficiency and lead to costly repairs or even engine failure.

Conclusion

In summary, both rust and sludge significantly harm diesel engines. Regular maintenance and proper storage conditions are vital to prevent these issues and ensure your diesel engine remains in top working condition. Taking these precautions can extend the engine’s lifespan and maintain its efficiency, ultimately saving on repair costs and downtime.

What are some common questions related to diesel truck maintenance and operation?

Common Questions Related to Diesel Truck Maintenance and Operation

Maintaining and operating a diesel truck often comes with a variety of questions, especially for those new to diesel engines. Here are some common queries and solutions that can keep your diesel truck running smoothly.

How Do You Charge a Diesel Truck with Dead Batteries?

Charging dead batteries in a diesel truck requires caution and the right equipment. Here’s a step-by-step guide to help you:

1. Use a Dedicated Battery Charger:Invest in a durable old-school battery charger, preferably with a selectable amperage of 25 to 30 amps. This allows you to control the charging rate.
2. Avoid New Smart Chargers:Some modern computerized chargers might not detect a completely dead battery. Opt for manual chargers for better reliability.
3. Apply a Small Load:Connecting a simple 12-volt light can help the charger recognize the battery.
4. Home Charging:Keep a battery charger at home to avoid frequent trips to a garage. This is especially useful since some places may not fully charge your battery.

How Do You Re-prime a Diesel Engine After Running Out of Fuel?

Running out of diesel can introduce air into the system, which requires priming to resolve. Follow these instructions:

1. Refuel First:Always start by filling the tank with diesel.
2. Bleed the Fuel System:
   • Locate the bleed screw on top of the fuel filter. Loosen it 3 or 4 turns.
   • Manually pump the priming pump until the air is expelled and only fuel is visible.
3. Fuel Injector Pump:Inspect the side of the injector pump for a small bleed screw. Loosen it slightly to allow air out.
4. Continue Pumping:Pump the prime pump 20 to 30 times until it feels firm. This indicates that air has been sufficiently removed.
5. Crank the Engine:If you don’t see fuel at the injectors, repeat the bleeding process before further cranking to avoid battery drain.

Additional Tips for Diesel Maintenance

• Avoid Prolonged Cranking:Extended engine cranking can deplete your battery quickly.
• Regularly Check the Alternators:Modern alternators can be sensitive to heat, so consider upgrading to high-performance versions if needed.
• Understand the Fuel System Layout:Air tends to accumulate at high points in the system, so be thorough when bleeding.

By staying proactive with maintenance and understanding the intricacies of your diesel truck, you can extend its lifespan and ensure reliable performance on the road.

What maintenance steps are necessary for a diesel truck that has been unused for a long period?

Essential Maintenance Steps for a Long-Idle Diesel Truck

Reviving a diesel truck that has been sitting idle involves several critical steps to ensure it runs smoothly and reliably. Here’s a detailed guide to help you through the process:

1. Battery Maintenance
   • Check the Batteries:Begin by inspecting the battery caps and filling each cell with distilled water to the recommended level.
   • Charge Thoroughly:Use a multimeter to check the charge; aim for a voltage reading around 28.8 volts for optimal performance. Allow the batteries to charge fully to ensure they hold the charge properly.
2. Fluid Inspection
   • Oil, Antifreeze, and Other Fluids:Examine the levels of oil, antifreeze, and other crucial fluids. Top up any low levels to maintain adequate lubrication and cooling throughout the engine.
   • Belt and Hose Condition:Inspect the belts for signs of wear and ensure that all hoses remain flexible. This step is crucial to prevent any leaks or breakages.
3. Safety Preparations
   • Chock the Wheels:Before proceeding with engine checks, ensure the truck’s wheels are securely chocked. This adds an extra layer of safety when you perform other maintenance tasks.
4. Fuel System Check
   • Refuel with Diesel:Verify there’s enough diesel in the tank. If necessary, refuel to ensure you have an adequate supply for testing engine performance.
   • Priming the Fuel Pump:If equipped with a hand primer pump on the fuel filter, loosen the handle by about four turns. Pull the handle outward until it stops, and then push it back in to prime the system effectively.

Following these steps will help ensure your diesel truck is in prime condition after sitting unused, safeguarding against potential issues and prolonging its lifespan.

What steps can be taken to ensure a diesel truck’s engine starts after being idle for a long time?

Essential Steps to Start a Diesel Truck After Prolonged Inactivity

When a diesel truck has been idle for an extended period, ensuring a smooth start requires some crucial steps. Here’s a comprehensive guide:

1. Battery Maintenance

• Inspect and Refill:Begin by checking the battery cells. Carefully remove the caps and fill them with distilled water if needed. This ensures optimal performance.
• Recharge the Battery:Fully charge the battery, aiming for a measurement of 28.8 volts using a multimeter. This indicates the battery is holding a proper charge.

2. Vehicle Fluid Checks

• Check Fluid Levels:Examine all essential fluids including the engine oil and antifreeze. Make sure each is topped up to the correct level.
• Inspect Belts and Hoses:Look over the belts for signs of wear and ensure the hoses remain flexible to avoid future breakdowns.

3. Safety Precautions

• Secure the Vehicle:Before igniting the engine, chock the truck’s wheels to prevent accidental movement.

4. Fuel System Preparation

• Fuel Levels:Confirm there is an adequate amount of diesel in the tank to prevent air pockets in the system.
• Priming the Fuel System:If available, utilize the hand primer pump found on the fuel filter. Loosen the handle with approximately four turns, pull it out fully, and then press it back in to eliminate air and ensure a smooth fuel flow.

By following these steps, you’re promoting a hassle-free engine start while minimizing the risk of potential damage from extended idleness.

How can you start a diesel truck that has been parked for years?

How to Start a Diesel Truck That’s Been Parked for Years

Bringing a diesel truck back to life after it has sat idle for years can be a rewarding project. Here’s a step-by-step guide to get you started on this mechanical revival journey.

1. Check the Batteries

• Inspect and Recharge:Remove the battery caps and inspect the fluid levels. Refill each cell with distilled water if needed.
• Charge Up:Use a battery charger to ensure the batteries reach a full charge. You’ll need them to register about 28.8 volts using a multimeter to ensure they’re functioning well.

2. Inspect Truck Fluids

Before attempting a start, verify all essential fluids:

• Oil and Antifreeze:Make sure both are at adequate levels. Replace them if necessary to avoid engine damage.
• Belts and Hoses:Check for any signs of wear. Belts should be intact and hoses should be flexible and free of cracks.

3. Chock the Wheels

This safety step is crucial. Place wheel chocks securely around the wheels to prevent any unintended movement while you work on the truck.

4. Fuel Up

• Assess Fuel Levels:Ensure there’s enough diesel in the tank. Diesel quality could degrade over time, so consider replacing or supplementing old fuel.
• Prime the Fuel System:If your truck has a manual primer pump on the fuel filter, loosen the handle by about four turns. Pull the handle up fully and then press it back down until resistance is felt. This will help in pulling fuel into the system, ensuring that any trapped air is expelled.

5. Final Preparations

• Inspect Before Starting:Double-check all your previous work. Look for leaks, ensure connections are tight, and keep a fire extinguisher handy as a safety precaution.

By following these steps, you give yourself the best chance of successfully starting a diesel truck that hasn’t run in years. Remember to proceed slowly and methodically to avoid unnecessary issues. Good luck!

What are the potential risks and costs of starting a diesel truck without proper preparation?

Understanding the Risks and Costs of Starting a Diesel Truck Without Proper Preparation

When you’re gearing up to start a diesel truck, taking shortcuts can lead to a host of problems and costly repairs. Here’s a detailed look into the potential risks and consequences:

1. Neglecting Fluid Levels

• Engine Oil:Failing to check the engine oil can lead to severe engine damage. Running on low or dirty oil may cause overheating or excessive wear on engine components.
• Coolant:Skipping a coolant check could result in the engine overheating, leading to expensive repairs or even complete engine failure.
• Transmission Fluid:Insufficient transmission fluid can cause the gears to grind or slip, resulting in premature wear and costly transmission repairs.

2. Ignoring Brake Maintenance

• Brake Fluid:Low or old brake fluid can reduce braking efficiency, increasing the risk of accidents and expensive damage to the braking system.
• Brake Pads and Rotors:Worn brake pads and rotors compromise braking performance. They need regular checks to avoid further damage to the brake assembly and ensure safety.

3. Overlooking Tire Health

• Tire Pressure:Incorrect tire pressure can affect fuel efficiency and handling, possibly leading to a blowout. Checking tire pressure is a quick way to avoid these issues.
• Tire Tread:Worn-out tire tread can decrease traction, especially in wet or slippery conditions, raising the risk of accidents.

4. Skipping Electrical System Checks

• Battery Health:Ensuring the battery is fully charged and the terminals are clean prevents starting issues which could leave you stranded. A weak battery can also put additional strain on the alternator.

5. Potential Financial Impact

• Costly Repairs:Ignoring these essential checks and maintenance can not only lead to the risk of immediate breakdowns but also escalate repair costs, sometimes running into thousands of dollars.
• Increased Downtime:The time your truck spends in a repair shop is time it’s not being utilized for work or transport, which can lead to a financial loss, especially for commercial operations.

Proper preparation is not just an option; it’s a necessity to keep your diesel truck running smoothly and economically. Regular inspections and maintenance can prevent unexpected failures and safeguard your investment.

What are the steps to prepare a diesel truck that hasn’t run in a long time before attempting to start it?

Steps to Prepare a Long-Dormant Diesel Truck Before Starting

If your diesel truck has been sitting idle for an extended period, follow these essential steps to ensure it’s ready to start safely and effectively.

1. Check and Charge the Batteries

• Inspect the Batteries:Start by removing the battery caps and inspect the electrolyte levels. If they seem low, carefully fill each cell with distilled water.
• Charge the Batteries:Use a battery charger to fully charge the batteries. A healthy battery should read approximately 28.8 volts on your multimeter when fully charged.

2. Check Essential Fluids

• Oil Levels:Ensure the engine oil is at the appropriate level and in good condition.
• Antifreeze:Check the coolant levels and top off if necessary. Make sure the antifreeze concentration is adequate for the expected temperature conditions.

3. Inspect Belts and Hoses

• Belt Examination:Look for any signs of wear or cracking on the belts. Replace them if needed.
• Hose Check:Ensure all hoses are flexible and not brittle, which would indicate aging or imminent failure.

4. Secure the Truck

• Wheel Chocks:Place chocks around the wheels to prevent the truck from moving unexpectedly during preparation.

5. Fuel System Preparation

• Fuel Level:Confirm that there’s an adequate amount of diesel fuel in the tank.
• Prime the Fuel System:If equipped, use the hand primer pump on the fuel filter. Loosen the handle about four turns, then pull it out completely before pushing it back in to prime the system.

By following these steps, you’ll minimize the risk of damaging your vehicle or experiencing issues once you power it up. Always proceed carefully, and consult a professional mechanic if you’re unsure about any step in this process.