Rebuilding my 5.9 Common Rail

[Yo Hoot]

Lookin good!

 

[AlaskanCummins]

Two things:



One, you're re-build is looking VERY good and I like your attention to detail.



Two, I LOVE my Espar and am sure you will love yours too. My wife said that it was the best eleven hundred dollars I have ever spent on any of my trucks!

 

[Shadrach]

Having an Espar, as well as heated seats, dual A/C and up grading to the factory 6 pak CD, from a wrecked 03, helps my wife swallow the cost and time a bit better. :-laf People ask me why it is taking so long to get the truck on the road. It's the detailing and installing all the accessories that are slowing me down, but doing the job right the first time will save me hassles in the long run.

Shadrach

 

[Walker1]

Wow, that's nice work!!

 

[Shadrach]

She runs

Oo. SHE RUNS Oo. After some delays ( kids birthday party, family wedding, work etc ) I finally started up my truck last night for the first time and no knocks or leaks. I would have had it running sooner but I made one mistake. When I installed the G56 instead of the NV5600 I didn't realize that the trans adapter was different. The G56 bolted up to it and the started fit OK but the old one is thicker where the starter mounts and the drive wouldn't mesh with the ring gear. I spent yesterday pulling the drive shafts, t-case, trans, clutch and flywheel so I could change the adapter and then put it all back together before we could start it last night. I used a South Bend clutch.

I still have to do rear brakes and finish some wiring ( it's never really finished anyway - right ). It came with half a tank of fuel, so I will fill it up with fresh stuff when I get it on the road. It will get the oil and filter changed real soon as well as the fuel filter after the first tank. I have access to a chassis dyno so I will get it broken in on there.

This truck has been sitting for 3 years now so I am anxious to drive it to see what else it needs before I go camping with the family. It has to go to Dodge for the H46 recall still.

Shadrach

 

[thomasrmmr]

oil pressure sender ?

Anybody venture to guess what caused all the carnage?

does any one realize that dodge took the ecm and uses a oil idiot lght type [on,,off;] type sender and the ecm tells you what the oil pressure SHOULD BE AT THAT RPM NOT WHAT IT IS interesting that instead of 4 to qts low you drive it till it blows if you havent put on A SEPARATE OIL GAUGE AND WARNING LIGHT cummins tested mine after i trouble shot y my sun gauge said 17 lbs and my dash gauge said 45 ? interesting another toyota rec all sounds like a class action lawsuit to me !!! tom

 

[Yo Hoot]

Where did all the oil go?

 

[thomasrmmr]

i got a leak ,,, i think in a 4000 psi hose on BYPASS FILTER , BUT AFTER I TOOK OFF THE HOSE I PRESSURIZED IT AND NO LEAK SO AM NOT SURE BUT I HAD OIL ALL OVER THE PASSENGER SIDE FRONT TO BACK , BUT CUMMINS HAD TO SHOW ME THAT DODGE TOOK OUT THE LOW POWER OR LIMP MODE WITH THE CHANGE TO THEIR PROPRIATARY ECMS IT SHOULD HAVE WAVERRED MY OIL GAUGE IT DIDNT TILL I WAS 9 QTS LOW , NICE LAWSUIT !!!ANYBODY ELSE HAD THESE PROBLEMS CONTACT ME !

 

[Shadrach]

Well I had my new engine running several times but as I was about to back it out of the shop for the first time it just quit. It would turn over but not a cough or sputter. I spent lots of time checking things out even had the Cummins mechanic who had helped me build the engine come out and help me check things out. Everything we checked was OK. Since I couldn't check everything I had it trailered by a friend to the Dodge dealership where I know some of the guys. ( The local auto club -AMA- wouldn't give me a free tow because I have a deck on it and not a box ) As we were unloading it, I was steering, the back window blew out . I was planning on having a new windshield installed anyway but now I needed a rear slider as well. The deck has a headache rack so there wasn't much room for the glass guys to get in there.



The Dodge tech asked if I had a good used CP3 pump to try as he wasn't getting enough pressure. ( It's an expensive part to try. ) I borrowed a used pump and that solved the problem. I ordered a new one and will change it myself later. I was supposed to take the "new truck" on holidays with the trailer earlier this month but I still had too many details to finish. I borrowed my brother's van. A free 2008 E350 for a week is better than not going and having the family made at you :-laf. I now have 2 weeks to get it finished before I am off again. Unfortunately the dyno I was going to use for break in is down for repairs, so I will just hook up the trailer and go for a "test drive".



BTW I decided to install "real" oil pressure and coolant temp gauges. So I now have those 2 and my air pressure gauge on the pillar and the pyro, boost and fuel pressure on the the dash. I like gauges

 

[Shadrach]

Went for my first "trip" today with the "new " truck - about 350km ( 225 miles ) round trip. I was only towing a sled trailer, empty down and with a pick up box on it coming back, but it runs smooth and has lots of power for me. It did throw a code , so I will have to change the crank sensor tomorrow. I find reverse too fast for backing up, especially with a low short trailer. Since I haven't installed my front drive shaft yet I just put it in 4 WD Low and it worked great. It sure is nice to finally have a diesel to tow with. We leave on Monday for a week in the mountains with the TT. Shadrach

 

['strokeThis_'07]

Dang that looks great! I just melted two pistons, so I'll be pulling mine and rebuilding it. Did you use a Cummins manual or find another book somewhere, for torque specs and such?

 

[Shadrach]

I have access to Cummins Quick Serve on Line and all the specs are on there. That and a Cummins mechanic. Shadrach

 

[bsappington]

Bump to the top.

 

[AH64ID]

Great build... How is it treating you after a few months of use?

 

[Shadrach]

Engine runs great. Didn't drive it much this winter- my defroster door broke. I did pull with it back in August and let's just say it pulls a bit better than my old V8 Dodge I want to dyno it soon, although I don't expect any big numbers, just to do a proper engine break in. I only have about 5000 kms ( 3000 miles ) on it so far. Looking forward to pull the TT with it this summer. Shadrach

 

[rbattelle]

Shadrach, maybe this is a silly question, but do you have a service lift?

Just wondering if you did all that transmission/tcase/etc removal and install without a lift.

Beautiful looking engine. I sure wish they'd paint them at the factory like they show them in advertisements.

-Ryan

 

[KDancy]

Nice build, I'm using it to help me on the 2004. 5 that we are re-building. What cam did you wind up going with? What paint type did you use?

 

[Shadrach]

I use a transmission jack and installed the trans and t case one at a time with the truck up on jack stands. My buddies shop has lot of tools and equipment but a hoist isn't one of them.

I used Cummins "Apex Red" and "Bracket Black" and this cam Camshafts for Dodge Cummins 88-93, 94-98, 12 Valve Engines, 98. 5-2002 24 Valve Engines, 2003-2007 Common Rail 24 Valve Engines

I see you state 19. 1 mpg. I check my overhead the other day when I was running empty on the highway and when I changed it from metric to US it was reading 19. something. I realize that these things are not real accurate at times but I do check the mileage by hand at times as well.

BTW assuming the CDN and US dollars were equal ( and they are close ) we are paying around $1. 10 per litre for diesel right now - the equivalent of about $4. 17 per US gal . That's over $140 for a fill up.

Shadrach

 

[AH64ID]

I see you state 19. 1 mpg. I check my overhead the other day when I was running empty on the highway and when I changed it from metric to US it was reading 19. something. I realize that these things are not real accurate at times but I do check the mileage by hand at times as well.

I would say more often than not they are out to lunch...



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