'05 Budget Engine Rebuild

[Dysfunctional Vet]

Decided to rebuild my son's '05 before he goes off to college next year. The truck has 226K on the odometer. I got it at around 209K. I don't think it was treated well, at least not the engine and trans. Getting to the point: what should I be looking out for while rebuilding this engine? Brittle parts, common issues, required tools, etc.. The engine is/was running strong, but blow-by, exhaust smoke and oil consumption was getting excessive. Same as everyone else, I'm on a budget (got three kids to put through college in the next 6 years, expendable income is not available). Looking forward to all your usual sage advice.

 

[AH64ID]

If you can squeeze it into the budget I would highly recommend the 03-04 style piston and injector tips. You don't need to go with the fancy QSB480 pistons, thou they are sometime cheaper.

Be sure to check the cam/tappets for wear.

I don't recall what a Genuine Holset HE351 rebuild kit costs, but I don't recall it being cost prohibitive.

 

[MGreer]

I'm in the same boat, mine has 160k on the clock. Got the head removed and have cracked rings in hole #5. Doesn't look like it will clean up with a hone, looking for a local machine shop. How long has it been running with the excessive blow by?

 

[Dysfunctional Vet]

I'm in the same boat, mine has 160k on the clock. Got the head removed and have cracked rings in hole #5. Doesn't look like it will clean up with a hone, looking for a local machine shop. How long has it been running with the excessive blow by?

I've been limping it along for about 5 months. Didn't have a choice. I'm hoping I don't need machine work. There's an abscenly long wait for machine shops here. Plus, budget doesn't have slack for machine work. I originally thought I could get a decent rebuilt long block. Then I saw the prices, just about soiled myself. Please give me any Intel you learn from your project.

 

[Dysfunctional Vet]

If you can squeeze it into the budget I would highly recommend the 03-04 style piston and injector tips. You don't need to go with the fancy QSB480 pistons, thou they are sometime cheaper.

Be sure to check the cam/tappets for wear.

I don't recall what a Genuine Holset HE351 rebuild kit costs, but I don't recall it being cost prohibitive.

Never heard of QSB480s. I'll have to look those up. If I get the pistons do I need matching injectors? I was told that 04s and 05s have different pistons. Told if I got the wrong piston my 05 injectors would slam into incompatible piston reliefs. I think I got that info from a tech rep at CPP. Definetly don't have funds for new injectors right now. Appreciate the input.

 

[AH64ID]

At a minimum you need matching injector nozzles, which has to do with matching spray pattern to the bowl and not with clearance issues.

The QSB480 is the HO marine 5.9 motor. The pistons are the same bowl design as the 03-04, but the pistons have been double heat treated to be more durable, as well as a minor difference on the lip of the bowl. Basically the strongest OE piston for the 5.9. The stock 03-04 pistons are also very strong, so for a stock level rebuild it really comes down to which you can find cheaper... if you need pistons at all.

 

[Darkbloodmon]

Following...

I'm seeing consistent "low" mileage rebuilds and excessive blow by engines(mostly stock applications) in passing weather on marketplace or groups. It's making me nervous about adding power to my 03 after the extensive work I've done to it to bring it up to speed from the previous owners. 232K to date with goals of 550/900.

What is causing these engines to have excessive oil consumption requiring a rebuild so "soon" ?

 

[AH64ID]

What is causing these engines to have excessive oil consumption requiring a rebuild so "soon" ?

On the 04.5-07's a lot of it is due to the piston design and what it does for carbon production. The carbon damages the rings.

 

[Darkbloodmon]

On the 04.5-07's a lot of it is due to the piston design and what it does for carbon production. The carbon damages the rings.

Is it so bad that good oil or water meth injection can't help it? Or is it just a matter of more frequent oil changes needing to be done?

 

[MGreer]

I would guess in my case an injector over fueled and got things too hot. When I pulled the head, about four of six pistons had a lot of fuel in the bowls.

 

[AH64ID]

Is it so bad that good oil or water meth injection can't help it? Or is it just a matter of more frequent oil changes needing to be done?

It's piston design. It's a major part of why the oil is so black, and fast. The carbon accumulates above the rings and then breaks off into the rings. I am not sure oil or OCI would have much of an effect. The harder they work the better they probably are.

 

[bcbender]

Never had any issues with my 04 engine!... engine, injectors, turbo were all stock and I ran a TST on 4/4 pushing it up around to the limits of the stock turbo, I think it was around 350/750 ish... but I tried not to run it more than a slight haze at WOT.

 

[Darkbloodmon]

OCI

What's this acronym? Never mind "oil chance intervals" context clues... I was thinking it was referring to an injection type.

 

[Darkbloodmon]

Getting to the point: what should I be looking out for while rebuilding this engine?

It probably goes without saying but a good seal job on the bottom end gaskets and such, rear main front, oil pan, timing case/cover, cam seal etc. I really recommend using Permatex high-tack gasket sealant on hard to align gaskets, o-rings or any sealing surface with a gasket really. It's essentially an oil, fuel and water resistant high temp glue that stays tacky indefinitely. I used it on my oil pan gasket, oil pickup tube, and rear main housing. It's also a good thread sealer.

Engine mounts while its out if they look bad.

Cp3 if its weeping diesel.

 

[Darkbloodmon]

It's piston design

Would coated pistons help in anyway; ceramic bowl, dry film skirt? Ploydyn comes to mind. I considered sending my rebuilt turbo and manifold to them for ceramic coating before I found a local company near me that does coatings for Nascar and dirt track teams. Living within walking distance of the Charlotte Motor Speedway has its benefits sometimes.

 

[Timd32]

. Same as everyone else, I'm on a budget (got three kids to put through college in the next 6 years, expendable income is not available).

I have a specialty 5.9 tool set I picked up here from a member, I will take a look at what is actually in there, you would be welcome to borrow it if it's of use. It came with all sorts if gadgets, in general it was not selling to anyone so I picked them up.

I don't have a manual but Quick Serve has updated a little while ago, make sure you register there with your ECN to get the diagrams and engine specific info.

A true Cummins manual might be a good buy.

If folks know of some stuff tool wise I would do a tool share for some stuff that just sits in the box that I have accumulated over the year if it's useful to you.

What's your time frame for tear down and inspection?

I have an old friend who works for me part time was a machinist amongst a lot of things I will have him look over my stuff and let you know the condition and if it's decent enough to use for something like this. It's all stuff like Central, Snap-on, and other mechanic grade stuff.

Others might have to help ID some of it and if it's really needed with the engine torn all the way down as some of it is for use with the accessories installed.

Either way good luck with your build.

 

[Timd32]

Here are some pics of the tool kit and some odds and ends that came with it.

If you need tool part numbers let me know.

 

[Dysfunctional Vet]

Following...

I'm seeing consistent "low" mileage rebuilds and excessive blow by engines(mostly stock applications) in passing weather on marketplace or groups. It's making me nervous about adding power to my 03 after the extensive work I've done to it to bring it up to speed from the previous owners. 232K to date with goals of 550/900.

What is causing these engines to have excessive oil consumption requiring a rebuild so "soon" ?

I have a specialty 5.9 tool set I picked up here from a member, I will take a look at what is actually in there, you would be welcome to borrow it if it's of use. It came with all sorts if gadgets, in general it was not selling to anyone so I picked them up.

I don't have a manual but Quick Serve has updated a little while ago, make sure you register there with your ECN to get the diagrams and engine specific info.

A true Cummins manual might be a good buy.

If folks know of some stuff tool wise I would do a tool share for some stuff that just sits in the box that I have accumulated over the year if it's useful to you.

What's your time frame for tear down and inspection?

I have an old friend who works for me part time was a machinist amongst a lot of things I will have him look over my stuff and let you know the condition and if it's decent enough to use for something like this. It's all stuff like Central, Snap-on, and other mechanic grade stuff.

Others might have to help ID some of it and if it's really needed with the engine torn all the way down as some of it is for use with the accessories installed.

Either way good luck with your build.



Thanks, appreciate the offer. So far I've picked a barring tool and a 4 valve compression tool from Geno's. I'd previously bought a fan wrench from Geno's. Already used the wrench, and bought the other tools in anticipation of use. I think I might have to buy a ring compression tool but I hope not. If anybody knows a good hack for ring compression I'd appreciater that too.

 

[AH64ID]

Would coated pistons help in anyway; ceramic bowl, dry film skirt? Ploydyn comes to mind. I considered sending my rebuilt turbo and manifold to them for ceramic coating before I found a local company near me that does coatings for Nascar and dirt track teams. Living within walking distance of the Charlotte Motor Speedway has its benefits sometimes.

Likely not, it's the shape of the bowl on 04.5-07's. You don't need to worry with your 03.

 

[Dysfunctional Vet]

I have a specialty 5.9 tool set I picked up here from a member, I will take a look at what is actually in there, you would be welcome to borrow it if it's of use. It came with all sorts if gadgets, in general it was not selling to anyone so I picked them up.

I don't have a manual but Quick Serve has updated a little while ago, make sure you register there with your ECN to get the diagrams and engine specific info.

A true Cummins manual might be a good buy.

If folks know of some stuff tool wise I would do a tool share for some stuff that just sits in the box that I have accumulated over the year if it's useful to you.

What's your time frame for tear down and inspection?

I have an old friend who works for me part time was a machinist amongst a lot of things I will have him look over my stuff and let you know the condition and if it's decent enough to use for something like this. It's all stuff like Central, Snap-on, and other mechanic grade stuff.

Others might have to help ID some of it and if it's really needed with the engine torn all the way down as some of it is for use with the accessories installed.

Either way good luck with your build.


Appreciate the offer. I'm trying to build a tool list 'cause I'll probably be tearing down my '07 w/in a few years...she's got 332K on the odometer. No issues yet but I think I'm on borrowed time. I've already purchased the tech manuals, valve compression tool and barring tool from Geno's. I'm hoping I don't have to purchase a ring compressor tool, so if anybody has a tool hack for that task I'm all ears. Getting nickled and dimed on my not-so-budget rebuild.
Gonna see if I can pull the engine this weekend. Hoping my Harbor Fright engine stand will hold the 6BT w/o crushing like a millennial at a blue collar job. Will post picks when I can. Yall please keep the advice coming.