BBR's 1991 F-350

[BBR]

Since it is an older truck, I decided to make a project thread for this thing. It is a 1991 F-350 dually. EFI 460/E4OD trans 4.10 gears in the rearend. Power windows, power locks, cold AC. The odometer shows 79k miles and from the condition of the truck, I believe it.

It needs a few things, but seems pretty solid. I need to find a hitch, a tailgate, a bed mat, and a toolbox. It lived most of it's life in Bakersfield, CA, then did a short stint in Odessa Tx, before it ended up here. Paint is decent, it was top halfed at some point in it's life but looks pretty good.

[SuperBuickGuy]

Plans? Godzilla?

[BBR]

I don't have any engine swap plans for it right now. It runs great and doesn't do anything weird. I wouldn't rule out a Godzilla or 6bt swap someday in the future though.

I am going to do some brake work to it, and maybe do dual exhaust and I *might* swap the 4.10's for some 3.73's or 3.55's. I will not be towing anything super heavy with it so it should be fine with a taller gear.

[SuperBuickGuy]

I don't have any engine swap plans for it right now. It runs great and doesn't do anything weird. I wouldn't rule out a Godzilla or 6bt swap someday in the future though.

I am going to do some brake work to it, and maybe do dual exhaust and I *might* swap the 4.10's for some 3.73's or 3.55's. I will not be towing anything super heavy with it so it should be fine with a taller gear.

I laughingly say what when I tow my Corvette with my motorhome that the motor in the motorhome is the spare motor for if things go pearshaped.... nice to see that you're following the same idea

[silver_bullet]

May want to peruse this option.... :https://bankspower.com/collections/c...ngine_7-5L-Gas

[fatguyzinc]

if i remember right--pull those twin air tubes off, hacksaw the "trumpets" off the end of the plastic it attaches too = 15hp free.

as soon as you start the truck, hit the "o/d off" button on the shifter. dont use o/d at anytime unless its on freeway, and NEVER
use o/d when towing.

do the "lightning valve body" mod. helped a ton on my old F350 with the E40D trans. i also did the transgo shift correction deal.

you cannot overcool an auto trans, and you cannot make it shift too hard--chirping tires at anything over half throttle upshifts
sounds good to me.

enjoy that big ol dinosaur. wish i could find one here!

[BBR]

I laughingly say what when I tow my Corvette with my motorhome that the motor in the motorhome is the spare motor for if things go pearshaped.... nice to see that you're following the same idea

Great minds?.

[BBR]

if i remember right--pull those twin air tubes off, hacksaw the "trumpets" off the end of the plastic it attaches too = 15hp free.

as soon as you start the truck, hit the "o/d off" button on the shifter. dont use o/d at anytime unless its on freeway, and NEVER
use o/d when towing.

do the "lightning valve body" mod. helped a ton on my old F350 with the E40D trans. i also did the transgo shift correction deal.

you cannot overcool an auto trans, and you cannot make it shift too hard--chirping tires at anything over half throttle upshifts
sounds good to me.

enjoy that big ol dinosaur. wish i could find one here!

I have a set of air tubes with the trumpets cut off.

I on my other E4OD I put a Punisher valvebody in it and was very happy with how it shifted. I may do the same for this one.

[BBR]

The plastic striker pin sleeves were gone, so I installed a new set. Man, the doors shut NIIIIIIIIIICE now!!!

[BBR]

Drove it home after work today. I stopped and put 10 gallons in the front tank and then tried to fill the rear but it was full. Gauge shows empty on front and 1/4 tank on rear so it looks like we have some stuff to sort out.

[BBR]

Started working on brakes today. This stuff is big. Haha.

The pad are thin and the hoses are toast. Hubs will spin forever if you give them a whirl.

[BBR]

I hope the guy at Ford that thought it was a good idea to run the brake line through the frame and attach to the backside of the shock tower got fired and banned from designing motor vehicles ever again.

It's sooooo hard to get the hard line attached to the new rubber line!!

[andy30thz]

Started working on brakes today. This stuff is big. Haha.

The pad are thin and the hoses are toast. Hubs will spin forever if you give them a whirl.

I always have to laugh when people say "bolt-on wheel spacers are DEATH!" They would probably panic if they knew how all dually front wheels are attached.

NICE!! Always loved that body style. This one looks pretty clean. Seems like there are a few low buck mods that make them roll with a little more pep without messing up OEM reliability....but its been quite a while since I looked into it!

[BBR]

New hoses, pads, and I adjusted the rears. One rear was close, the other was not.

Pedal is better, but still lower than I would like. Kinda like it does not have enough volume It stops fine, you just have to push it a long way to get there. The master cylinder was replaced in 2017 or so and that got me wondering if they put the wrong one in. Like a smaller one for an F-150 or something.

So I started doing some research and found A LOT of folks with the same problem. I finally found a reference to a Ford TSB about this very problem in the later 90's models. Their fix is to use a master cylinder with a larger bore. The stock one is 1.125" bore and the replacement is 1.25". More research showed that others have successfully applied this same TSB to earlier year model trucks. I found the right one on Rockauto and I ordered it this morning.

While I was crawling around under it I removed some previous owner weirdness under the bed. There is an electric fuel pump under there and best I can tell it was used to transfer fuel from a bed mounted reserve tank to the front tank. There is a plugged rubber line from the pump the pokes thru the bed floor. The other line runs from the pump up to the top of the front tank filler tube. I removed all the wiring and some bracketry that I think was for a bedside step. I will pull the pump out later and remove/plug the hoses.

I looked and looked for the tank selector valve. Never found it. There is a good reason for that. From what I read, 1991 models (maybe others?) don't have one. The fuel tank selector switch just turns on the in-tank pump for whatever tank you have selected.

[SuperBuickGuy]

I "upgraded" pads on my Colorado. Stopping went from "awesome" to "frightening." They weren't worn out but I replaced the scary ones with OEM and got amazing back.

One 'trick' I do on my trucks is balance the stopping by replacing the pads with harder or softer options. The easiest way I found to figure that out was by warranty - the lower the warranty, the more aggressive (read softer compound) the pad.

anyway, hopefully the hydroboost is enough to let you go with a larger bore master - if it is, you'll be dragging your rear tires through every stoplight with the best of them.....


oh and damn you, I'm looking at duallys now. I want something nice, 2wd, old, and Dan's diesel in it.