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Engine/Transmission (1994 - 1998) Huge slice of Humble Pie

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Dear Abby,



Started out at 0700 to change my springs to 60#. At 1700 I gave up in dispair, nah, in utter depths of black dispair. :(



Bought one of Geno's Lisle valve compressors. Handles were too long so I made myself a stubby set which works much better. :) Moving right along. Used the "crossover" method to locate TDC, i. e. #6 exh. closing and intake starting to open - work on #1.



I take the pedestal off and compress the spring. BUT the spring, valve, and collets (keepers) just move up and down on the seals. Doesn't bottom on the piston. Can't even get close to having the collets want to cooperate. Crank the spring up, move the compressor, spring, retainer, and collets up and down, wiggle back and forth - nothing. Poke and prod the collets - nothing.



Paranoid about dropping a valve down the tube - it's been the kind of day that it seems that beast is just lurking waiting for me to... . Doah!!!



Take a break at noon and search TDR for miracle cure. No new insights.



Consequently, I switch back and forth between the Dowel pin and the crossover method for locating TDC. Rotate engine over enough times to cause premature cylinder wear. Never can get the dowel to find it's little bitty hole. Equally paranoid about stuffing the puny little sucker and then shearing off the nubin as I blithely continue rotating the engine. What an ingenious design and location. :eek: Bound and determined to use the crossover method.



Nagging questions:

*Am I TRUELY at TDC - if so why doesn't the valve bottom out? How much slack or play should there be? At what point is #6 at TDC - when the intake starts down?



*Is the compressor just not reaching far enough down on the spring to compress sufficiently so it will bottom out? I seem to get about a quater inch play. Changed from the cam handle to the bolt with no apparent gain or success.



*Is there a method to hold the end of the valve? Thinking about a piece of surgical tubing over the end. I'm not inclined to remove the injectors and huff air. Especially since I would have to fashion a puller first.



*The little devil sitting on my sholder telling me, "Look Ol'Dog if you can't even get the intakes on #1 or #2 to budge, just what do you REALLY think your chances are going to be on #5 and #6, aye? Better bunch it before you screw up so bad you'll be taking the head off"



The only thing that kept me going was reading just how plumb easy it has been for the rest of you liars. :-laf "Yep, took me a couple of hours. " "Watch out, cuz' the collets practically hop themselves off" My pride and confidence in my abilities is thoroughly trashed. Thinking about taking up cooking, vacuming, and maybe knitting, if I feel lucky - whimper, whine. :{



Sincerely,



Hang Dog in Moran
 
Fume... mutter... mutter... . cute!. That's it, kick me when I'm down, rub it in, put the boots to this ol'dog :{ :-laf



I really think I need to get an even longer bolt to replace the cam handle and hook even farther down on the spring. This hopefully should give enough play to bounce off the bottom, aye?



(Does anyone really know how to type the Canook Aye, aey, Ae, Ay,???? :confused: )
 
Don't swap your work clothes for an apron just yet, Ol'Dog. You'll get it. I can't offer much more than moral support as I haven't attempted a spring swap on my CTD. As for TDC, I'd recommend the dropped valve method or hanging in there and getting the timing pin to engage. It took me a long time to get the pin to go in and I dang near ruined my hands but it did finally go. Here's what I did:

1) sprayed the crap outta the timing pin housing w/ penerating oil.

2) let it sit for an hour or so.

3) worked the pin back & forth as much as it would move and spun it in the housing to loosen it up.

4) used my barring tool to find close to TDC on #1

5) wedged my hand against the pin as well as I could and put all the pressure I could on it while slowly barring the engine over (this part really didn't feel good).



Eventually the stupid thing went in. I have big hands (which didn't help) and long arms (which did help). I could rotate the engine and apply quite a bit of pressure on the pin at the same time.



The nice thing is, after you do find TDC you can mark your harmonic balancer and it'll be easy next time.



Good luck, man!



-john
 
Before you install the compressor, a gentle tap with a small hammer to the side of the retainers will loosen the keepers,allowing the spring to compress and move free of the valve. Hope this helps.
 
I'm new in the diesel repair/mechanic work. But with a gas engine all you do is pull the spark plug on the cyl. Build a adapter for your air hose that screws into the spark plug / injector hole, and apply the air hose. The compressor should apply enough pressure to hold the valve up allowing you to compress the spring and replace them one cyl. at a time. Just remember that all valves for that cyl. must be closed when applying the air pressure. As suggested by hsmith tapping with a small hammer will help free the keepers.
 
The answer to the Canadian question I believe is "Eh!" or "Eh?" kinda like "Dude" or "Dude!" or "Duuude!!" or last but not least "Dude?" which means are you behind the door with a butcher knife
 
The valves are very long,if you are close to tdc for that cylinder it will not disappear but it will be able to drop some ;) The most important thing is have a magnet in your hand... ... . you DO NOT want to drop a keeper. As many other jobs touted as easy on this board they are not being totaly honest :-laf :-laf



Bob
 
As to the TDC pin, I believe you can pull the pin clear out of its hole, remove the keeper and "O" ring. Then put it back in. It will be much easier to push in and you will be able to "feel" the hole better. When you get done, put it back the way it was.
 
With much trepidation I faced the beast again this AM. Compressed the spring. Took an upside down 60d nail, a small ball peen, and gave a gentle tapon top the spring retainer - Voile! Changing the bolt that came with the compressor to a 3/4" longer one helped get the 60# in without much problem.



Pray for me because numero 6 is next :eek:. And that I don't loose a collet - 41 miles to town.



Thanks for all the moral support and advice. Yesterday I had tapped on the top with no luck. If only I had changed the bolt and used the nail yesterday I'd be done.



Of course had to asked God's forgiveness for all the cussing and hollering yesterday. Now after all the boo hooing and whining I'm back in business. :{ :rolleyes: Rolled up the apron, put down the knitting needles, and put back on my coveralls. :D
 
TrailDog... ... ... ..... You better stop asking God's forgiveness on here. We are a very diverse group, we are. And somebody just may protest you and your lack of sensitivity. You must consider the non christians.



. . Preston. .
 
Gulp

Borrowed a sweet pencil magnet. Absolutely can not imagine doing this w/o. After #1 I spent quite some time doing the dowell, marking the dampner for next time (wonder why they don't do this?), and a long time getting the dowell and keeper-star washer back together for KEEPS (I hope). Also mark approximate 120* for the other pals. Amazingly this worked great too as I double checked watching the crossovers.



I did take the grommets out for #5 and #6. Then it was on to #2. Whilst doing the exhaust a collet went airborne. :eek: . Had the push rod holes covered with rags and I heard it "tink" somewhere near the front. Spent a long time looking to no avail. Not even angry... . just numb. :confused:



Fortunately, couple of folks are going to Idaho Falls tomorrow. Hope I can pick up some at Ron Sayers. If not I'll have to call Billings and have Rocky Mtn. Cummins mail some.
 
i do not see why anybody should find someone else praying offensive. i could see it if he asked everyone else to pray. it matters not to me if a person prays or not,or what that person chooses to pray to,or what a person chooses to call god. just my 10 cents worth. have a diesel day.
 
Hallelujah

Cruised over to Id Falls to pick up the company snowplow - 9' Boss V-plow. Stopped by Dodge - no keepers. Sent me to Jerry's parts - no keepers. Sent me down stairs to the machine shop - no keepers. Despair creeping up again. They spent 20-30 minutes search around and finally found Andre at Sage Creek who would pull some out of a head for me. Went over to Sage Creek and Andre gave me the keepers. Definately wanted to know what I was up to and where the other keeper went. Fortunately, could tell him I had the pushrod ports covered with rags.



Home at 1500 and off to the shop. Installing the rest of the springs was a breeze. and got the pup buttoned up.



Next morning up at 0600 and got the Painless wiring box installed, rebuilt the ebrake numatic unit with a $20 kit from BD, the exhaust brake on, the hoses hooked up.



Everything worked so I was on the road by 1030. Made it to BZ in time to pick up the Bosch skilsaw and sawsall before they closed.



Now I'm in Billings stuffing my face and enjoying family. Wife commented on how slow the 97 is compared to the other traffic. So, it was time to break the news about the 3. 55s I'm picking up off the classifieds just to fix this - timing is everything :-laf



Thanks for all your help and encouragement.



PS: Preston is just razzing me. So go easy on him.
 
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