Engine/Transmission (1998.5 - 2002) Replacing Head Gasket - help

[DMather]

I am about to replace the head gasket on my 02 5. 9HO due to an external coolant leak at the thermostat corner and I would like to know what other gaskets I will need. I currently have:



1- head gasket

6 - exhaust gaskets

1 - turbo gasket

1- intake manifold gasket

1- valve cover gasket



are there any other gaskets that I am overlooking?

 

[Wyomingcowboy]

You shouldn't need the intake gasket. The only part that needs to com off there is the air horn.

 

[SRadke]

You'll have to remove a couple of the banjo bolts in the fuel system. New banjo washers is helpfull but not required. There is also a gasket around the thermostat that may or may not be reuseable. When doing these jobs I just buy the upper engine gasket kit from Cummins. It comes with everything you need and then some for about $200.

-Scott

 

[DMather]

You'll have to remove a couple of the banjo bolts in the fuel system. New banjo washers is helpfull but not required. There is also a gasket around the thermostat that may or may not be reuseable. When doing these jobs I just buy the upper engine gasket kit from Cummins. It comes with everything you need and then some for about $200.



-Scott

That's exactly what I have been looking for... . but where do I find this upper engine gasket kit from Cummins for $200.



I've spent the past week searching for exactly that and the closest I've found it $450. (But, at the same token, I've found just the head gasket, EXACT same mfg and part number, available from $68 to $182 so maybe I just haven't found the right place. )



Is there a part number for the upper kit?

Who can I purchase it from?



I find it frustrating to spend twice as much time sourcing the parts as it does to make the repair. #@$%!

 

[SRadke]

Out here I use Cummins Northwest. I suppose you could too and have it shipped to you. (541) 687-0000

Write down your engine number off the data tag and call them up. They'll take a credit card over the phone and ship it to you.

-Scott

 

[Vaughn MacKenzie]

I've done some head jobs and felt the gasket set included a lot of gaskets that weren't really necessary and kind of a waste of $$$. I've had good luck reusing exhaust and manifold to turbo gaskets. I use a piece of wood and large flat screwdriver and pound on them to make new sealing ridges and reuse them. The valve cover gasket is designed to be reusable, only replace it if it's defective already.

The only gaskets you really need are the head gasket and two intake manifold gaskets
City Diesel - 24 Valve Stock Replacement Parts

I would just get a new thermostat while you're at it and use the gasket that comes with it.

 

[kscheffler]

Old thread I found searching. My head gasket is leaking near the thermostat also. How much should I expect to pay to replace a head gasket?

 

[Vaughn MacKenzie]

I think it's $140 for the head gasket, but it's been awhile since I bought one. But one slight change to my last post above, I strongly suggest replacing the intake cover gasket (the long one) because last year I was working on my '98 and mine was totally shot due to age and leaking. With the age these 24-valve are now it would be worth doing as a preventive measure, and they're cheap.

Also to do a proper HG job make sure the head is true, 12V heads always need resurfacing due to slight warpage, 24V not so much. If it needs resurface to make it true that's where most the cost you will incur comes from. Also I like using a new set of stock Cummins head bolts to play it safe, guys often reuse them if they're not stretched and do fine... they are very high quality.

 

[kscheffler]

Thanks Vaughn for the input. What do you think is a fair price to pay some one to pull head and replace gaskets? Should I install a stud kit or stick with the OEM head bolts? Is there any thing else I should hae worked on while the head is off?

 

[jgillott]

Thanks Vaughn for the input. What do you think is a fair price to pay some one to pull head and replace gaskets? Should I install a stud kit or stick with the OEM head bolts? Is there any thing else I should hae worked on while the head is off?

If you are not increasing power much over stock, you should be fine with stock Cummins head bolts. If you are moderately modified, or plan on being in the future, this would be a good time to do studs.

I've done quite a few head gaskets on 24-valves. It takes me an entire long day to do the job start to finish. I'm not sure what a dealership lists for estimated hours, but I would guess your looking at ~8 hrs labor at your chosen shop.

 

[SAndreasen]

I was quoted 800$ to do a head gasket on mine not including parts I decided to do it myself to many little things for a shop to do a half ***** job on so I just did it myself .

 

[kscheffler]

Are leaking Head Gaskets typical? I have a smarty that I run on Program 3 (fuel mileage increase) and RV 275 injectors and still have the boost valve installed. But I have a small weap of a leak beneath the thermostate housing.

 

[JR]

I wouldn't say they are typical but they do happen. Lots of factors involved including added power and boost, and lack of maintenance. If the ph in the coolant is allowed to get out of control long term it will begin to eat at everything in the cooling system including a hg.

 

[kscheffler]

Well it was not maintenance change antifreeze on 3 year cycles and check with strips and use Fleet Guard complete and Cummins NW tells me I change it too often. Hard to believe that the little extra timing from the smarty would do this and I never tow. Kind of disappointing that a motor this littly used has a leaky head gasket with 125k on the clock.

 

[JR]

It's hard to say what caused it without pulling the head and checking the sealing surfaces...are you the original owner?

If not it's possible it had been overheated at one time, or perhaps the previous owner wasn't as diligent as you in the maintenance department.
I would be comfortable in saying that your minor mods were not the cause of your issue there are lots of trucks out there running more boost and power than what you have on stock bolts and gaskets...sometimes you just draw the short straw. Sorry about your luck.

 

[kscheffler]

No I am the orginal owner; you are right about the short straw.

 

[SAndreasen]

Somebody had replaced the head on my engine and somebody had pitted the head either removing it from donor engine or while they were replacing it . It has what looks like a salvage yard part number etched into the head.

 

[JSchuh]

-I replaced head gaskets on both of my 01's. The 3500 had 140,000 on it and was leaking on the passenger side behind the thermostat housing not a bad leak but it bothered me, white streaks on the block. I'm not the original owner bought it with 93,000 ten years ago.
-I replaced the one in the 2500 at 330000, I'm the second owner, purchsed truck from my friend who bought it new. My friend said it had a small leak since it was new, dealer ship could never find it. When I decided to replace it it had gotten worse with the cold weather, in the winter, it started to leave a puddle on the ground. Found the leak was coming from the front edge of the head about in the middle. On inspection I found a 1/2 inch long channel about 3/16 wide in the head. There is a blind water jacket hole in the head that goes no where in the block the channel lined up with that, over time, I assume the channel got longer (electrolisis) and made its way outside of the silicon surrounding that port in the head. Or a deffect from the factory
The machine shop brazed the channel shut and resurfaced the head.
-both trucks have 275's and powerMAX 3's on 9 all the time. 40psi on 3500, 46psi on 2500. :-laf
-The factory head gasket set is the way to go. all the gaskets and new valve seals.
-The seals for the fuel return line banjo bolt on the back of the head do not come in the kit, reused old ones on 3500 (forgot to order). Installed new ones on 2500

 

[kscheffler]

A local vendor is telling me that I must have the head machined flat if they are going to replace the gasket or they will not warranty the repair. Is this typical they are estimating $1200 to machine the head. Would I not be better off purchasing an after market head with o ring and stud kit even though I don't need the extra boost?

 

[SAndreasen]

I had mine machined for 75 dollars usually they charge 150. 1200 sounds like a complete port and Polish job / head rebuild