5.9 Block problems

[Monroefiredog1]

Hi All,

I have a 02 2500 CTD that I have had for many years with no real problem. THen about 2 years ago it got a little hotter than it should have. It really didn't have the power after that, although it still ran pretty good. I decided to pull the head and have it checked. And while I was that far into it, I had an oil leak on the tappet cover, that I was going to repair also. Long story short, got it all back together and it would not run right. I kinda figured that the key-way on the injection pump was sheared a little. Took it all back down, found nothing wrong. Put it all back together, still would not run. I was just standing there looking at the engine, when I noticed a bubble from the #5 exhaust gasket. AT this point I think that it's either the block is warped, or a crack in the #5 cylinder wall. I have since started to pull the engine, it is now ready to lift out. My questions is what do you guys recommend at this point? Take it to a machine shop and let them check it, and repair it? Find a used engine? I have come to learn a lot on this adventure about the 5.9. I purchased a 5.9 with 147,000 miles on it. But when I got to looking at it closer it is a 2002 5.9 that was rebuilt by Cummins in 2016, however, it is only a 190 hp 5.9. I had no idea that a 5.9 Cummins engine could have this much less hp. I also learnt a lot about these 5.9 applications. I was not aware that Cummins rebuilds these engines for these older trucks on an ongoing basis. Anyway, I was just wondering what some with similar engine problems would do? Thanks in advance for you help.

 

[CVR222NV]

You might want to repost in the 2nd gen section for 24V if it's a 2002.

Take a look at this:

The Infamous Cummins 53 Block (dieseldatabase.com)

I recently rebuilt my motor and you can purchase long block replacements with a core exchange. Many are listed on Craigslist which are the cheapest. There are a few U.S and Canadian remanufactuers but a little more pricy. I had DFC Diesel out of Edmonton, Alberta, Canada do mine and so far happy as I shipped them my block and they rebuilt it to my specifications. If you are a do it yourself guy take a look at Dysfunctional Vet's thread as he is currently rebuilding his own 5.9 but it is a 3rd gen too. I tried that route with using a local machine shop in early 2021 and could not even get an estimate. You might have better luck in your area now. The machine shop should be able to tell you if your block is salvageable. I got lucky and was able to use my block after burning up piston number 4.