6.9 IDI Diesel and ZF-5 Trans Carnage! Project Brutus, Ep. 2

In Episode 2, we get the 6.9 IDI diesel engine fully disassembled with the help of fire and a large hammer, discover a major issue with the ZF-5 S42 manual transmission, and discuss our options for engine and drivetrain moving forward!!! Should we go with a 6.9 IDI, 7.3 IDI, 7.3 IDI turbo, Powerstroke 7.3, or a Cummins to replace the 6.9???
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Thanks!
Scott

[@rpetty]

Great build series. I’m just finding these now and can’t stop watching. Thanks

[@THEBULLETPROOFGARAGE]

Thanks! Glad you're enjoying the videos. Scott

[@traderz3399]

Please keep the idi videos coming we need more idi videos on youtube

[@THEBULLETPROOFGARAGE]

Hi TRADERZ - I'm going to do my best keep the IDI content coming! Scott

[@johnburrescia2699]

I'm so locked on with these videos. I need a Mr Roger's jingle leading me in to this 15 min of educational ride along. Keep it up. Let me know when your merch drops so I can represent. STAY BULLETPROOF!

[@THEBULLETPROOFGARAGE]

Hey John - Thanks for your interest and support! If you go to the main Bulletproof Garage page and click on the bell in the top right hand corner, you can choose to get notifications when a new video hits. No merch available yet, but when that happens, I'll make sure you're at the top of the list! Thanks, Scott

[@561ENTERPRISE]

Picked up a 89 last week. Did hear you let this go. Thank you for your service. See ya un Texas. Will be finishing up the series. 73's

[@THEBULLETPROOFGARAGE]

Thanks for your support! I'm back in Texas as of a month ago. Just in time for the awesome August weather!

[@keneldred9030]

On the transmission part, I believe I would leave the truck 2 wheel drive, saving the added $$ to get the transfer case and front axle assembly, to help you get whatever compensation you can back, from the engine expenses! Plus, to also help save you all that extra time, and work as well!

[@THEBULLETPROOFGARAGE]

Thanks for the input, Ken. Scott

[@drewh9594]

Scott, I’m just starting my own project build. 86 F250 extended cab, 7.3idi n/a swapped, with C6 auto. I can’t get enough of these videos and I’ll put on your series when I am wrenching on my own. Keep up the great work and PLEASE keep posting IDI content. Thanks!

[@THEBULLETPROOFGARAGE]

Drew - Sounds like a great project! I hope to have more IDI content coming in the future, but I do have a few musclecars that I need to finish, too! Scott

[@pharmdadfit]

Excellent videos. If you go 4x4 then also consider super duty axles. Very easy to find and inexpensive comparatively. If you can find some with 4:30 gear ratio then you will be better off for towing with the IDI. I’m looking forward to more from this channel.

[@THEBULLETPROOFGARAGE]

Hi David - You are correct - Super Duty axles are quite easy to find and affordable. The only problem is that I would want to change both axles since the Super Duty axles have a metric bolt pattern and I'd want front and rear axles to have the same bolt pattern. Thanks for your input, and I think you'll like what you see when Episode 4 is ready! Scott

[@grndiesel]

I'm not an IDI expert but I did spend many years maintaining and modding my 1986 F250. I'd go with the Dana 60. Did it to my truck and it rides surprisingly well as long as you don't go with crazy hard shocks. As for the engine, anything used that you get will be a roll of the dice unless you rebuild it from the ground up. If you want to go cheap, find another used 6.9 IDI and call it a day. If you want a truck that's usable and reliable, build a 6.9 IDI and turbocharge from day one. Install ARP head studs and boost it to 10~12 PSI. Plenty of power and the head gaskets will hold up just fine over a very long period with those mild boost levels. You're likely tempted to go with the 7.3 IDI factory turbo. It's a good engine with some decent internal mods to improve durability. Even without studs, the bigger head bolts on the 7.3 make it far better able to survive big boost as well (relatively big boost...we're not dealing with a powerstroke here). I just can't get past the cavitation risk that comes with thinner cylinder walls. Looking forward to following this build!

[@THEBULLETPROOFGARAGE]

Hi David - thanks for taking the time to provide detailed feedback! I agree with you on the Dana 60 -- it's a rock solid front diff and the ride shouldn't be terrible. I had a 2003 Excursion 4x4 - Dana 60 on leaf springs - and the ride was fine. There's a company - Sky Offroad - that make a kit to swap a Dana 60 into a 2WD brick nose truck. If I go this route, I plan to use their kit. On the engine, I agree that any engine that ends up with a turbo should be purpose-built for it. I'm familiar with the head stud issues (7/16" for 6.9 and 1/2" for 7.3), and agree that any boosted IDI should get head studs. I'm also not a fan of the cavitation issues on a 7.3, and I'm sure hoping the one I sourced is standard bore. If not, my backup plan is the 6.9. I plan to download Episode 3 in a few days, so pretty sure you'll know how this all plays out! Scott

[@randylugo2885]

I just found your channel, what a hidden jem. Very entertaining and educational, just subscribed

[@THEBULLETPROOFGARAGE]

Welcome aboard, Randy! Scott

[@caleblee4856]

Who else chuckled when we freed the engine and the rod caps fell😂? I am not making fun of you I promise. Great job sir. You’ve got yourself a new subscriber through your amazing work. Great job sir.

[@THEBULLETPROOFGARAGE]

Welcome aboard Caleb and thanks for the kind words! Scott

[@cryoine7194]

I started to look into this because I came across a 1992 E350 with the 7.3 IDI so I'm doing my homework into these engines/vehicles

[@THEBULLETPROOFGARAGE]

Thanks for checking in! Scott

[@wesleemiller]

Great video.

[@THEBULLETPROOFGARAGE]

Thanks, Weslee!

[@paulchrisman2392]

I've had both the 6.9 & the 7.3 both idi I like the 7.3 so much better than the 6.9. The 6.9 had the smaller head bolts & they cracked the heads so easy.the 7.3 just had more guts & run better. I'd go with the 7.3 over the 6.9 just for easy of part aquiring reasons.

[@THEBULLETPROOFGARAGE]

Hey Paul - Check out the later videos - I'm going with a 7.3 IDI turbo. Thanks for the comment, Scott

[@josephmclovin9763]

I love my 87 idi. Good luck!

[@THEBULLETPROOFGARAGE]

Thanks, Joseph!

[@darrenbarnes5401]

I bought a 1990 f 250 with 7.3 idi, seized, 2 cans of pb blaster freed it up

[@THEBULLETPROOFGARAGE]

Man, I wish mine would have been that easy to free up. Nice work.

[@DependableAutoTruck]

solid axle for sure

[@THEBULLETPROOFGARAGE]

Check out the latest videos on the channel where I installed a Dana 60 up front! Thanks for your input, Scott

[@landof6377]

Yes 4x4 and D 60!! Zf5 out of a f450 with parking brake on if take it off I think transfer case will bolt up too

[@THEBULLETPROOFGARAGE]

Lando F - well, that's the route we have taken, except for the F450 ZF-5! Check out some of the more recent videos!!! Thanks for your input, Scott

[@hendrikzenga5654]

Hate to say it but you might be money ahead if you buy a running 4x4. I always want to save old non runners too tho.

[@THEBULLETPROOFGARAGE]

Hi Hendrik - I agree 100%, but I have a soft spot for old abandoned trucks. I enjoy getting them back on the road and saving them from the scrap yard.

[@warrenksanbornjr.6643]

Yes definitely make it 4x4

[@THEBULLETPROOFGARAGE]

Warren - that process is just about done! If you check out my later videos, the truck now has a Dana 60 solid axle. Thanks for your comment, Scott

[@randysrestoration]

Hope not a fummins swap. Hoping a 7.3 turbo version. I came across a nice diesel for my ‘66 N crew cab. Makes 2050 TQ at only 1000 RPM! Only 11k mi on it.

[@THEBULLETPROOFGARAGE]

A 7.3 IDI turbo would be a nice swap! I think a diesel swap would make sense in your N crew cab, but what diesel that would fit in there makes 2,050 ft/lbs???

[@randysrestoration]

@@THEBULLETPROOFGARAGE i figured i would see if you were paying attention! It’s a 2023 x15 only fummins i would swap. 605hp 2050tq. When i looked uo specs saw the tq at 1000 rpm. Soft rollover brand new truck. It auto trans too. Perfect for N Crew. I wonder if the 2spd eaton will hold the power?

[@THEBULLETPROOFGARAGE]

@@randysrestoration - the 2 sp Eaton should be fine until you start doing burnouts!

[@paulm.6437]

Get a 7.3l idi, 93, or 94 Ford with turbo- it wil last past 500,000 miles!

[@THEBULLETPROOFGARAGE]

Hey Paul - Well, you're close! I sourced a 1994 turbo 7.3, but the block ended up being junk, so I got a low mile 7.3 from a 1988 plow truck. Check out some of the other videos for more details! Thanks, Scott

[@paulm.6437]

Dana 350, with the single axle?, and auto 4x4 hubs

[@THEBULLETPROOFGARAGE]

Hi Paul - I sourced a Dana 60 from a 1990 F350 for the truck -- check out some of the later videos for details. Thanks! Scott

[@traderz3399]

Go with the dana 60 4x4

[@THEBULLETPROOFGARAGE]

Hi Traderz - Excellent recommendation! Check out Episode 4 when it airs for more details on what direction we're going to take! Scott

[@tryandtakealaska3797]

a 1 min moment of silence vigil a celebration of life is held at the end of the video to celebration the life and death of the poor f350. born in 1987 he lived a fruitful life over time had some issues with his balls getting rusty in the bed we don't know if he push but we do know he pulled in the bed till he cracked under the pressure and died in a field he puke vile green stuff and his heart just stopped and after being lost in a field for 20yrs his dead body was found and a man is trying to resurrect him from the dead getting a heart transplant and fixing the cracks that lead to his death so watch the videos and see if his resurrection is successful. hehe thanks for sharing

[@THEBULLETPROOFGARAGE]

Love it! Thanks!

[@johnreid4348]

Where are you located?

[@THEBULLETPROOFGARAGE]

I was in Virginia when I was filming the Brutus episodes, but I moved home to Texas last summer.

[@power_joke_havin-a-stroke9281]

I have a 84 6.9 idi ive been working at little by little. I got it to start up and idle drive down the feild but only started with either. One day while idling she started sputtering and died. Now it slowly cranks and cant get it to hit on either at all, (i just give it a quick squirt). It seemed to have a noise like a tapping sound when it ran but not sure if thats the issue or not. I was told it was diesle clatter, but i feel that something is off and there was no shavings in the oil. Would anyone know what i need to look at? Im a noob to diesle mechanics and really want to save the engine, it only has 84,000 og miles theres a clip of the noise on my channel thanks.

[@THEBULLETPROOFGARAGE]

If it sputtered and died while running that sounds like a fuel issue to me. Do you have enough diesel in the tank? Have you changed the fuel filter? As for the hard starting issue, if it's not spinning over fast enough, it may not start. If you have two good batteries, check your battery cables for corrosion and good connections on both ends. Also, I'm guessing your glow plugs are not working; you may need new glow plugs (ONLY MOTORCRAFT!!!) or a glow plug relay. Recommend you join oilburners.net and post in the IDI forum there, along with ford-trucks.com. That's the best place to go to diagnose engine problems. Good luck!!! Scott

[@shespractical7272]

Banging noise, rough running and hard starting can all result from air intrusion into fuel line paths. Trust me I know.

[@power_joke_havin-a-stroke9281]

@@shespractical7272thanks, guess i will have to check it again been through her several times but im not a very seasoned mechanic so i probably missed it

[@rayscrafield2106]

I have to ask, why would you want to invest that much money in that old rust bucket? Is it really worthwhile? I'm not a Ford fan so I have to say, NO!

[@THEBULLETPROOFGARAGE]

Old rust bucket? You must be from the desert southwest, because that truck would be considered to be rust free for the rest of the country! Thanks, Scott

[@rayscrafield2106]

@@THEBULLETPROOFGARAGE As a matter of fact, sunny So. Cal. But you yourself showed the frame rails where the core support was sitting that had rotted out. I rest my case. It's a rust bucket. Most Fords are. JMHO. LOL>

[@THEBULLETPROOFGARAGE]

@@rayscrafield2106 - Brutus wasn't mint, but it wasn't a rust bucket, either. We'll have to agree to disagree.

[@rayscrafield2106]

@@THEBULLETPROOFGARAGE I was just trying to yank your chain a bit. No problem. I like you style and your series so I'll hang around. I guess if you want this sort of truck and don't mind the expense, all is good. Keep up the good work. I'm enjoying it.

[@rexgexnortowmader5165]

I'd ask, do you NEED 4 wheel drive? If you do, again should have pulled the nose as a unit. Other comment suggested going Super Duty. Super Duty (F450 in those years) parts as axles may be abundant, but rotors, bearings, seals, and other parts might be hard to find and discontinued, and EXPENSIVE! What is the Purpose for the Truck? Will it need 4x4? Looking forward to episode 3. Thank You

[@THEBULLETPROOFGARAGE]

Does it need 4WD? Good question, but I'd rather have it and not need it than need it and not have it. As for the axle swap, I went with a 1990 king pin Dana 60 (check out the episode on the swap) so I would have the same bolt pattern front and rear. I didn't want to swap out the rear diff so I wasn't mixing and matching 10 lug or metric bolt patterns. Thanks for the comment! Scott

[@dinocroes5693]

Hi friend i think it will be super with a 4 wheel drive with yhe same sizr of engine

[@THEBULLETPROOFGARAGE]

Hi Dino - well, the 4 wheel drive conversion is done! Check out the later videos for more details. Thanks for the comment! Scott