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Changing 1994 6.5 For 1990 6.2

Yep, Mike. It's a good feeling when things go better. I must have held my tongue just right. I definitely went about things just a bit different today, and that really made a difference.

Don
 
Some questions have been rolling around in my mind around breaking in the refreshed motor. I know what was recommended many years ago, and have since read recommendations that are completely opposite. I do have some ideas of what should be done, but what are your experiences, recommendations? The big concern is the new rings, and keeping the motor from ending up with any oil consumption.

Also, are there any recommendations for breaking in the rebuilt 4L80E transmission?

Don
 
Load the rings and do so ASAP, but, not 100% duty on them. Vary throttle and engine RPM during break in. Don't hit the freeway and set the cruise... It needs a good amount of pressure to get the 2nd ring to break in. I have seen military engines where only 1/2 the 2nd ring face was wearing even after we got the engine used and were towing with it.

Oil consumption is rings, valve stem seals, guides, and CDR...
 
Thanks for the reply WW, as I was really hoping you would chime in. You appear to have a lot more experience with "refreshed" diesel motors than the average owner. What you are saying goes right along with what I've been reading and thinking. The lower end has already been broken in. The rings are the item that needs attention during break-in. Many of the articles I have found state, to varying degrees, that ring loading and varying RPM's are very important.

There is a road about a couple miles away that has a half mile hill, and then lots of up and down for about three more miles. If I do a few round trips, maybe staying out of fourth for the first few miles to keep the RPM's down, that can start the breaking in. Then, although it is Interstate, a few miles north of home the freeway has a hill that is about a mile long, with a few more miles of up and down. This hill, and a few of the smaller ones just north of there, slows the big trucks down to 30 to 40 MPH.

Don
 
Don't lug it.

Let off the throttle for a few seconds during the hill climb a few times to allow the rings to re-oil themselves. I think the main break in is done in ~500 miles.
 
I got an e-mail from Paypal this afternoon saying a package from Leroy Diesel was being shipped by USPS. The time listed by USPS for "A shipping label has been prepared for your item at 10:51 pm on September 29, 2015" is a bit confusing as I received the e-mail at 3:51 PM, and I think there is only two hours time difference from that part of Texas to Oregon. But, anyway, I figure the package will be somewhere on it's way tomorrow morning.

A great big THANK YOU goes out to all who have had a part in this. As soon as it arrives I'm going to have to go into seclusion to finish putting the motor back together, running, and initial breaking in of the rings. I know I won't make the first part of deer hunting season, but I will have until Oct. 14.

By the way, I have the Fluid Damper back on now. So, the seal driver is available to anybody who needs it.

Don
 
Just got back from post office. Your stuff was in the pile. Like I told Nate your gapless pissed on rings are on the way, among other thing.

Damned auto correct... I do believe the above should read piston rings.
Well, unless Don and Leroy have something going we are unaware of...
 
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I just checked the USPS web site and this is what I found, "Your item arrived at the Post Office at 3:48 am on October 2, 2015 in ALBANY, OR" YEEEHAWW!!!! Now that only means that sometime today it will be delivered. Out here in rural Albany the mail will arrive anywhere from 2 PM to 6 PM.

On another note, Leroy asked for pics of the build process. I have a tendency to get greasy, then say forget having to clean up to get pics, as that takes a lot of time. I promise to try to do better. Anyway, here's a few pics of how the motor sets currently.

Seal driver, over the crank snout after just driving the seal into place.
IMGP1479.JPG

The block, as it currently sets, with harmonic balancer in place.
IMGP1480.JPG

Other side of block.
IMGP1481.JPG

Injection pump. The set lines were difficult to see so I used a sharpie and put a black line beside the set line. I never loosened and removed the IP from the front housing, so theoretically the timing will be the same as it was prior to the tear down.
IMGP1483.JPG

Heads, waiting to be put back on.
IMGP1484.JPG

The blue room. My "workshop". I initially put up the "roof" for sun protection while working, then due to impending rain I added the southwest side curtain.
IMGP1485.JPG

I'm really looking forward to the arrival of the "package". I won't be able to do anything tomorrow as I will be attending church, yes, on Saturday. But, Sunday morning I will be starting the final assembly.

Don
 
I've been volunteering some maintenance repairs, mostly plumbing, at church for the past few years now that I have a bit of time to do so. Anyway, I spent some time there this afternoon and came home a few minutes ago to find a package on the front porch. Hmmm, says it came from Leroy.

Now, Sunday will be when I get to the rings, and other stuff. I'm looking forward to getting the pickup back on the road.

Don
 
so did the driver make it a fun job?

I giggled to myself the first time I used it. I thought to myself "Thats it? 3 whacks, under a minute, and we are done? Alot different than half an hour, a large socket, and two people...."
 
Do we have some pics of the heart transplant patient too? :)

The engine looks good! I have allways been curious as to how a 6.5L would look in the Detroit Diesel silvery blue paint they used on the 60 series 4 cycle 6 cyl. engines in the 90s.
 
I've only got a few minutes here, daylight is showing outside, so I have to get back at the pickup. I do have some more pics from the assembly, but have been spending very little time on the computer the past few days. And, yes, the driver sure made installing the front seal so much better and quicker.

As of last night the motor and transmission are in, but not fully bolted down or hooked up. That is today's job, and hopefully get it running and start the breakin process. I hope to have a few minutes time tomorrow to give a quick update and some pics before leaving to go hunting.

Don
 
I've got a quick question about ground wires. According to what I can find there are supposed to be three wires on the dipstick mount post on the back of the right head. I can only find two, a large black wire (about 12 ga) and the braided wire that runs to the firewall, and then down to the frame. I don't remember what I took off that post.

Can anybody give me info about any other wires, color, where they come from?

Don
 
IT'S ALIVE!!! As soon as I finish this post my son and I are leaving for hunting. I drove it a bit this afternoon to start the breakin, but this trip will have to continue it. We'll be going over the Cascades Mountains on the Santiam Pass, so that should be good for additional breakin.

We'll be back sometime Thursday. I will be able to add pics and details at that time.

Many,many thanks to all.

Don
 
You're brave taking the truck right after you got her running!
I did a 5000 mile trip in mine two days after I got mine fired up :)
 
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