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K1500 6.5TD overhaul

HighSierra86

Active Member
Messages
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45
Location
Northwest CT
So I know how much I enjoy reading everyone's "rebuild" and "project" threads, so I decided to start one of my own. Its nice to hear imput on ideas from everyone as well as share some of my own.

Now my 95' K1500 developed a nice engine oil leak a few months ago which began to bother me. I have managed to keep most of the major leaks under control with the exception of the valve cover gaskets without fully tearing anything apart. A quick inspection revealed that the front skid plate had worn through both engine oil cooler lines. I got lucky they didnt pop, but not a bad idea to keep an eye out for the same problem! Well now the lines are a simple fix (yes leroy i will be ordering a set soon:D) but I also noted a nice coolant leak as well. A quick pressure test revealed the leak coming from behind the timing cover.

Now I figured that if I was going to tear into the engine this far, i would just end up replacing one thing after another. Which is fine, but id rather just finish the job by rebuilding the entire engine. With 230K miles and a steady stream of blow-by from the dipstick tube, id say it is about time. Now the last few months I have been busy with work and the farm, so I havent had much time to work on the truck. But the last two weekends and a few late nights, the engine and tranny are out!

I have been slowly starting to disassemble the engine to bring it to the machine shop where I used to work. I want to get the block cleaned and magnafluxed for cracks before I go much farther. The block is a "141", which from my understanding, isnt the best, but not the worst. Still not too sure on my route for the rebuild, probably 18:1 compression with a holset, but the ATT is not out of the question either. I am in the process of trying to sell my 6.5 suburban to help cover the costs of this project, so funds will be based on what I can get for that. Sad to sell it, but at this point in my life a suburban dosent fit the need.

And as for other areas to cover with the truck...I am going to have the trans rebuilt while it is out. The fluid smells burnt and there have been alot of unusual noises coming from within recently. I also have alot of work to do in the engine bay with cleaning up the P.O's wireing, painting, and addressing the firewall insulation...or lack thereof. Im also going to tackle the interior so long as time/funds alow. I really like this truck and have no intentions of selling it, so I might as well give it a refresher!

I attached some photos of the progess so far. Still cant figure out why they are so small with photobucket. And just for the record...this is my third time writing this thread, as my lack of computer skills have deleted it twice :mad2:

-Nick

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Well, a month later and progress has been slow. Havent had much time, an hour here and an hour there. But just thought id share where I was at. Hopefully I can get it stripped down to a bare block today so i can drop it at the machine shop tomorow. Everything has looked good so far. Cylinder walls all look ok, not too much scoreing anywhere. Harmonic balancer is shot (big surprise). Heads are cracked in between valves (another huge surprise :rolleyes5:). The parts needed list gets longer with everything i see. Ah well. If im going to do it, might as well do it right.

-Nick

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Had to let the air out of the tires to clear the core support?:eek:
I really don't belive that the casting number of the block is all that important. Many of the supposed "bad" 506 blocks made 300,000 plus miles. I have 4 broken "599" blocks that are supposed to be the best. The "141" in my 95LD looked great inside at 280,000 miles other than the timing chain was very loose. Cloyes timing set is the best i've found. Very tight:thumbsup: Melling was very loose:nonod:
 
haha yea the air had to come out in order to clear. My engine hoist dosent have alot of lift, and the celing height is also low. Had to disconect one of the shop lights too! I was going to use the backhoe outside to lift it out, but with my schedual i didnt want to start outside and then have to leave it out in the rain. We are in the process of building a 40X60 shop/storage barn so height and room wont be an issue soon.

As for the block, I think it is hit or miss, as you say. Hopefully everything checks out ok. If the block is cracked im not sure what road ill be going down next. As for the chain, mine was quite loose also. not really a big surprise though.

What was a surprise was i pulled all the lifters today and found that one of the no. 8 cyl lifters had a large flat spot worn into the roller. Looked as though it hadnt been rolling for quite some time.

Dont have much left to do other than pull the pistons, crank, and cam. Hopefully I can get the block to the machine shop soon.
 
Well I found myself with some extra energy tonite after work and mowing grass, so i decided to drop the pan to pull the pistons and crank. And well...i wasnt too happy with what I found. Every main web is cracked :nonod: The center web is the worst with cracks that are almost all the way through to the cyl wall. So needless to say im not too happy about that. I have junk heads, junk block, worn out trans, and a truck with 230K. At this point in time I really dont have the money to be throwing at this thing. I loved the truck and was willing to dump money and time into it to rebuild most of it. But running around trying to find a crack free block really dosent fit the schedual or budget at the moment. Hopefully in a few years I can get back to it. Or if something falls into my lap, it might be even sooner. But i think for now this project is going to be on hold.

Ill load up some pictures of my wonderful discovery sometime soon.

-Nick
 
That sucks!:sad: Makes you wonder just how many 6.5s are driving around with cracks.
Lots of military 6.2s in PA. They go cheap some times especially if they are in lots of 2 or more. Saw some in ohio go for $200 for 4 engines. 4 of the 8 i got have the newer style heads with the injectors angled up :thumbsup:
 
Cracks that go from the main webs and up into the cyl walls is not a real common thing but, it happens.

My 506 squirt block had 2 nasty ones that went up and into the cyls (6-8) and hit green juice.

Scare up a 6.2 thats solid and use that for a foundation and then use a good set of 6.5 heads.

Many options.

The afternarket blocks are holding up fairly well so far out on this end of the world.

Two guys have them and so far the one with the most miles is about 50K and rolling.

Buying used 6.5 blocks is a gamble no matter what.

Some engine rebuild suppliers will sell used blocks that they inspect and mag first.

Small cracks in the main web outer bolts can be inserted with Lock and stitch inserts.

If the cracks are not below the depth of the holes the inserts are sweet.

Sorry to hear the bad news.


Missy
 
So i finnaly have some pictures here, none of the really bad crack, but what you see is the same on every main web....or worse. I think at this point and time I am going to buy a 95+ gasser just to get me through the plowing season or untill i finish this truck.

Ive also changed my mind on a build up for tis truck as well. If a near stock 6.5 engine block can be destroyed this easily, im not going to bother pushing the power envelope much further by adding low compression pistons and a holset. Im looking for longevity and mileage, not a dyno/drag truck. So i think ill look into finding a decent 6.2 short block that i can build from as bk95td says. Budget friendly and will put the truck back on the road with minimal issues and money hopefully.

What would the boost limitations be with a 6.2 bottom end and head studs? Safe enough for a gm8 or att??

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Well on a good note i think i made a decent score this weekend. Picked up a complete 98 gmc truck cab with power doors, tilt steering wheel, and no rust anywhere! Also got a complete radiator support with all coolers/radiator still attached, both front fenders, gmc grill and lights, coolant res., and a round style air box.........all for only $170!! Best yet, it came from a diesel truck so harness, guage cluster and everything else can be of use.

Ive been looking for a set of power replacement doors for my 96 for over a year now...and this was worth the wait. Just have to fill in the holes from the "west coast" mirrors and repaint. Ill be happy to swap the chevy work truck grill for the gmc one too!

Added a few pictures of the jd 410 and the cab for your viewing pleasure......

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So i think ill look into finding a decent 6.2 short block that i can build from as bk95td says. Budget friendly and will put the truck back on the road with minimal issues and money hopefully.

What would the boost limitations be with a 6.2 bottom end and head studs? Safe enough for a gm8 or att??

I went with a boyce equipment surplus 6.2 engine. They test run it and warranty it for 30 days or more. I forget. It was 1200 shipped to me. 6.5's if they have them are 1500 plus shipping.

I would change the precups on the 6.2 if I did it over. I used everything but the injectors and timing water pump steel plate. 6.2 heads, 6.2 DB2 IP retimed... I should have used the 6.5 injector lines for better fit. Get an oil line made and tap the OPS for the turbo. I did replace the head gaskets with 6.5 gaskets per Heath's recommendation.

Make sure you have new ebay manifolds as yours likely will not even bolt back up.

I ran 14 PSI sustained max boost and fuel way turned up for extended WOT pulls with a 28' trailer. ARP studs and no issues. Till it flattened an Elk. But that was 3 weeks and around 8000 miles of this abuse.
 
bk: Have you checked all those 6.2 blocks you bought for cracks?? How did it come out?




That sucks!:sad: Makes you wonder just how many 6.5s are driving around with cracks.
Lots of military 6.2s in PA. They go cheap some times especially if they are in lots of 2 or more. Saw some in ohio go for $200 for 4 engines. 4 of the 8 i got have the newer style heads with the injectors angled up :thumbsup:
 
So it has been a while since ive made any headway on this project and I think I need some advice.....To give you a quick refresher, the truck is a 95 with 230K miles and fisher snow plow. I have a cracked block, cracked heads, junk cam, and a transmission that really should be rebuilt. What im getting at here is that I am having a very hard time justifying dumping money into this truck. The parts list I have just keeps getting longer and i know it will just get worse as the project progresses. At this point and time the only thing the truck has going for it is that it is rust free and the fact that it is a factory 1/2ton diesel.

So I guess i want to know what you guys think I should do. I am leaning heavily on just selling the truck as a rolling chassis for parts after I take off the plow and some other goodies. But i really dont know what I should expect to get for it? It breaks my heart because this has been on of my favorite trucks I have owned (there have been many) but at this point in time I need to look at this from a financial point.

I would like to hold onto it until I had the time/money/space to rebuild, but I dont want it to just sit and rot to pieces either.........aarrgg

If i knew how to set up a poll I would do so.....so until then feel free to post

-Nick
 
I am sorta new to the 6.5 world, owned two in my life- one when I was a punk teenage kid, the other now (purchased in February 2010). I have heard of cracking issues, but is this a very common thing for all blocks? My current truck is a 93 6.5 my question is how durable are the 93 blocks? Anyone know?
 
I would look for a military 6.2 take out, some members have posted some pretty good prices. Then use new clearwater heads and your turbo and manifolds.


My current truck is a 93 6.5 my question is how durable are the 93 blocks? Anyone know?
The 93 should be a good block.
 
The poll start is at the bottom of the thread starter page.
A truck with no drivetrain isn't worth much unless you part it out. Parting out is a pia and lots more work and dicking around selling the parts.
I wait untill the bodies are rotted to hell or the frames are rotted badly to junk out.
 
I am sorta new to the 6.5 world, owned two in my life- one when I was a punk teenage kid, the other now (purchased in February 2010). I have heard of cracking issues, but is this a very common thing for all blocks? My current truck is a 93 6.5 my question is how durable are the 93 blocks? Anyone know?

Read post #4 . 93s are 599 blocks
 
HighSierra86,

Maybe I can chime in ..


From what I read, you can do without this truck. And that is the crux of the situation.

If you need the truck to work and is a part of your revenue stream, then yes by all means rebuild and rebuild well. But if you do not have the cash to fix properly, I would sell it all and pour the money into a "new" truck fund.. Build the fund over time, and when ready go out and buy the best well maintained, documentred truck you can find.

Emotions aside, if you do not have the cash, then holding on to the bits , will eventually turn to a heep of scrap. Its always a question of money!! There will always be trucks out on sale..

my 2 cents
 
Emotions aside, if you do not have the cash, then holding on to the bits , will eventually turn to a heep of scrap. Its always a question of money!! There will always be trucks out on sale..

my 2 cents

That kind of hits the nail on the head. I dont have the time or money to finish this project the way I would like to now. But i know if I hold onto it and it sits outside, it will only get worse. But on the otherhand there are alot of good parts on the truck that I would hate to do away with. I guess its an old farmer mentality, but I have a very hard time throwing out anything I may have a use for in the future.

And as barry said, parting it out is too much of a PITA to deal with so that really isnt an option. Ive been taking parts from the truck as I have needed them, so i suppose I will just continue to do so. Just a shame to see it go that way. But a truck in that condition wont be an easy sell, nor will even get enough money to be worth it.

Funny you mention the other trucks, as I just offered to buy a 98 1500 diesel a few months ago.:rolleyes5: I dont think the 6.5 bug ever leaves.
 
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