Welcome back to Hank’s Cars and Coffee. In Episode 2, we finally start digging into the 1995 Ford F-150, which has officially been parked for almost a year with a rod knocking 5.0. The plan: get this thing stripped down and ready for its new heart—a Mercedes OM606 turbo-diesel.
Before starting the teardown, I wanted to answer point out some of the reasons why I chose the OM606 over other common swap options like another 302, a Cummins, or an LS. In short, the OM606 is light, efficient, and unique. It weighs roughly the same as the 302 (around 460 pounds), makes comparable torque in stock form, and once paired with the 7mm mechanical injection pump I’ve purchased, it should easily push 300hp/350 lb-ft. Plus, I’m keeping my 4R70W transmission which I had rebuilt a few years ago, the transmission will be controlled with a US Shift Quick 4 controller in place of the stock PCM. Less wiring, fewer sensors, more mechanical control is the goal.
I’m not a mechanic by trade, so this whole process is equal parts learning experience and test of patience. I picked up a rolling tool cart from Home Depot, filled it with the basics from Harbor Freight, and got to work. Instead of pulling the motor from the top, I decided to remove the whole front clip including grille, radiator support, radiator, condenser, transmission cooler, headlights, and some other small bits. It’ll make life easier later when fabricating motor mounts, mocking up intercooler piping, and fitting the OM606 properly.
Somewhere around 15 minutes in, I hit my first snag, a hard-to-find bolt behind the headlights (Dumb Things Counter: +1). After that, it was just sweat, humidity, and the realization that this process is basically Legos for adults except hotter, more expensive, and dirtier.
A Little Of My Background
The teardown during this stage is straightforward, lots of bolts and immediately forgetting where they go, but that is a problem for future Me. While working, I decided to take a little time to share some about my background. My primary career is in marketing, videography, and multimedia creation you can check out my portfolio at www.hankejohnson.com. I’ve been behind a camera since high school, and after years working in marketing and motorsports media with The Motor Enclave and a few other private motorsports country clubs, I decided to branch out on my own as a freelancer in order to get some personal time back in this stage of my life and give me the freedom to spend time with my friends, family, fiancé and to pursue projects like this. Hank’s Cars and Coffee is my way to combine storytelling and automotive work, turning my personal project and passion into a documented learning experience for myself and others.
By the end of the day, the front end was stripped, the driveway was still clean (mostly), and I was a little more confident about what comes next. The engine’s still in, but we’re close. Episode 3 will cover pulling the motor, cleaning everything up, and preparing for the OM606’s arrival.
If you’ve got questions about this swap, especially if you’re thinking of doing something similar, drop a comment or DM me at @hankejohnson or @hankscarsandcoffee on YouTube, Instagram, Facebook, or TikTok. I’m trying to share every step in detail so that others can follow along—or learn from my mistakes.