My Truck's engine blew on the way to MCACN...

[njsteve]

I bought this baby brand new back in 1995. K2500 6.5 diesel, 3/4 ton 4x4. Atlantic Blue and silver. 123,000 miles. Still has original paint and a perfect body. We were attempting to tow my 24 foot trailer from NJ to a car show out west. I got 130 miles into PA and pulled into a rest stop to use the facilities. She was running smooth as silk (always a bad sign!)

I then noticed whitish smoke puffing out the exhaust when idling. Almost like what you see on start up on a cold day. Only it was after 130 miles. When I stepped on the pedal, the white smoke was much more evident. Since I didn't like the looks of that we turned around and headed home slowly.

I got within 30 miles of home when the mushroom cloud of white smoke came out the exhaust and the coolant blew out of the bypass hose off the reservoir. The truck's coolant temp was only running 185 degrees at the time (verified by infra-red heat gun on the hoses, the block and the radiator). Looks like a blown head gasket.

I was able to limp the truck off the exit and only travel another 1/4 mile to a safe parking spot which just so happens to be only 2.9 miles from my co-driver's home (This becomes a rather important fact next...).

I then call the wife and ask her if she renewed the AAA like I asked her to a couple dozen times before. She of course says, "Oh, I was going to do that later today." I then tell her to do it now. She gets on the AAA web site, and it crashes. So she drives into town and renews. (all while I am sitting with broken truck and trailer).

She then calls me back and gives me the Good News/Bad News. Good news, we are members again...bad news; they only tow 3 miles during the initial 7 day waiting period. Jeez - isn't the national gun buying waiting period shorter than that?

Luckily the destination is just under 3 miles and we get the truck towed by AAA to a safe spot. Once there I check to see if the truck will start. The engine starts right up and immediately smokes again. So I shut it down after only a couple seconds.

I call to a buddy (I'll call him "Joe" since that is his real name) who then loans me his brand new Dodge Cummins 2500 HD. (Now THAT's a friend!) and we make the trip up and back to the show.

So, here we are a week later. I just got back from the trip and checked the truck. It does crank slowly- no hydro lock. I checked the oil and there is no water in it. It is still black and not milkshake. But, the oil level is about 2 inches above the fill line! Did the non-firing cylinder(s) filled the crank case with diesel from a damaged injector? I will note that immediately after the initial brake down I checked the oil and it was at its normal level, so this must have happened over the week of sitting?

I know the truck isn't worth much on the open market but we have owned it since new and it is a member of the family - you know the drill: this truck brought pregnant wife to delivery room, carried the kids home from the hospital when they were born, took us on family vacations, dropped kids off at college 18 years later, over the years carried several of my dogs home for burial when they passed away...

So, I could use recommendations on replacing the 6.5 or repairing this engine. I have heard about the AM General replacement engine but I would like some advice from those of you who have more experience with 6.5 diesel engine replacements and/or repairs.

Sadly, the book value of truck is around $4,500 and a new engine is almost double that price.

Who do you recommend?

Thanks, NJSteve

P.S. Buying a new truck is out of the question with current economic conditions and daughter in college, etc.

If only I had a penny for every viewing of my old '72 T/A restoration thread on here and on the PerformanceYears site...104,814 + 1,990,194 pennies = $1,048.14 + $19,901.94 = $20,950.08 <<GRAEMLIN_URL>>/grin.gif

http://www.yenko.net/ubbthreads/ubbthreads.php/topics/99416/72_TA_New_Project#Post99416


Oh, and I only have two more days of my mandatory waiting period before I can get my truck towed back here from my buddies house 30 miles away... <<GRAEMLIN_URL>>/rolleyes.gif

[Smokey]

You could feel worse...like walking into the dealer for a $7500 bill for set injectors like on a Duramax. Tear it down and see what you have. It could be something simple. Your a fairly smart guy who can take care of it.

[markjohnson]

Steve, I've been hearing about several different companies that sell conversion kits to swap newer Cummins diesels into older Chevy trucks like yours. Apparently, it's become a pretty popular thing to do lately. Here's something from a quick Google search:

http://dieselconversion.com//knowledgebase/Conversion-Overviews/GM-Chevy-1978-1999-Diesel-Gas

[Chevy454]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: Smokey</div><div class="ubbcode-body">You could feel worse...like walking into the dealer for a $7500 bill for set injectors like on a Duramax. Tear it down and see what you have. It could be something simple. Your a fairly smart guy who can take care of it.
</div></div>
That's a tad high, even for a dealer, lol...I wanna say GM books 10 hours, I'm thinking the tab for replacing all 8 on LB7 was just shy of $4500. Still not cheap, though... [Edit: it could be more I suppose if it was a new Dmax, but they don't have the catastrophic injector failures the LB7s had.]

Swapping a Cummins in those early c/k's is fairly common it seems, but the best bang for the buck would be to simply drop a 454 in it.

[njsteve]

She is home now.

http://www.yenko.net/ubbthreads/pics/usergals/2013/11/full-1359-8198-suburban_towed_.jpg


Of course the local NJ AAA started balking at the tow saying that it they only allow one tow per breakdown incident but the PA AAA lady (Mary) who I dealt with last week, was very forceful and worked on my behalf reminding them that they previously stated that the vehicle would be towed the full distance after the waiting period expired.

While I was on hold with the Mary, I drove right down to the local NJ AAA office where my wife signed up and was sitting outside with my headlights pointed inward at the front desk and looking very much like &quot;Heisenberg&quot; of <span style="font-style: italic"><span style="font-weight: bold">Breaking Bad </span></span>fame, especially after having not shaved for a week and wearing my black hat. Maybe that convinced them to OK the 30 mile tow home.

[njsteve]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: markjohnson</div><div class="ubbcode-body">Steve, I've been hearing about several different companies that sell conversion kits to swap newer Cummins diesels into older Chevy trucks like yours. Apparently, it's become a pretty popular thing to do lately. Here's something from a quick Google search:

http://dieselconversion.com//knowledgebase/Conversion-Overviews/GM-Chevy-1978-1999-Diesel-Gas </div></div>

That looks like a job for Kwhizz-Man...well beyond my abilities (and back muscles)

[Craig_Maiorana]

what part of NJ steve? .... I may still have a few connections

[njsteve]

Hunterdon County (Central Jersey)

[Craig_Maiorana]

Let me ask around... a few of my buddies are diesel mechanics. I'm originaly from ocean county

[njsteve]

I was originally trained as a diesel mechanic...but as they say, &quot;A man's got to know his limitations&quot;

And working on one of these modern contraptions is beyond mine.

[Canuck]

&quot;That looks like a job for Kwhizz-Man...well beyond my abilities (and back muscles)&quot;

Offer it up to him as a Power Tour Vehicle and he will get it done.

[YENKO DEUCE REGISTRY]

Hunterdon? Like next to Lambertville? Nice area, plenty of deer! <<GRAEMLIN_URL>>/grin.gif

[njsteve]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: YENKO DEUCE REGISTRY</div><div class="ubbcode-body">Hunterdon? Like next to Lambertville? Nice area, plenty of deer! <<GRAEMLIN_URL>>/grin.gif </div></div>

Yes. Hey, maybe I should check the air cleaner and see if the truck accidentally ingested an uninsured deer, and that caused the implosion. <<GRAEMLIN_URL>>/grin.gif

The deer overpopulation is crazy here. I have to honk my horn every morning to get the heard out of my driveway so I can leave. Those dang, pesky, meddling, teenaged, deers. No respect I tell ya!

[Material_Boy]

Steve,
Enjoyed talking to you at the MCACN. With what you went thru to get your car there your attitude and sense of humor was no different than what it is on the site whenever you post. You have an awesome original/unrestored Firebird!. Don't touch it! You can't find em like that.
Trivia note: A few years ago someone on this site started a thread about weird color combinations on cars they had owned over the years. NJsteve posted about a suburban that he owned many years before and I knew right away that we had met some 25 years ago in the hotel parking lot for the Musclecar Nationals in Atco NJ. My truck and trailer was parked next to his truck and trailer and while you couldn't help but notice the hideous color combination of the Suburban, what got my attention more was this guy working on this hemi car (Charger I think)to go out and thrash it on the drag strip the next day. I looked at wife, rolled eyes and said this guy is nuts to do that to this car. I know guys----that's what they were built for. Any way we spoke for a few minuets, wished each other luck,(I was car showing-he was drag racing) and never saw him again until Sunday at the MCACN. Steve, I hope you get your problem with the Suburban straightened and it doesn't cost you and arm and a leg in the process. The color combination of the present Suburban is more pleasing than the last one I saw. LOL.

Dave

[njsteve]

Great meeting you too, Dave.

You know, 25 years ago I was thinking the exact same thing about you and your car back then: How could this guy be so crazy as to be cleaning and polishing and primping such a nice car and then just show it. How could he NOT want to beat the hell out of it? <<GRAEMLIN_URL>>/grin.gif

That was the one-of-one, original paint, orange/white 1971 Hemi Charger sunroof car. It's in the Wellborn Collection now. It ran 13.837 at 101.35 if I recall correctly.

BTW for those who don't remember that old thread, my old 1986 K2500 Suburban was medium gold with a bright blue interior. I think the color was called <span style="font-style: italic">Jersey Tan Mom Bronze</span>.

Here's a couple photos, one of the charger and the trailer and one of the Charger at Atco in 1988.

http://www.yenko.net/ubbthreads/pics/usergals/2013/11/full-1359-8200-71_hemi_charger.jpg
http://www.yenko.net/ubbthreads/pics/usergals/2013/11/full-1359-8201-71_hemi_charger_1.jpg

[Material_Boy]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">Great meeting you too, Dave.

You know, 25 years ago I was thinking the exact same thing about you and your car back then: How could this guy be so crazy as to be cleaning and polishing and primping such a nice car and then just show it. How could he NOT want to beat the hell out of it? <<GRAEMLIN_URL>>/grin.gif

BTW for those who don't remember that old thread, my old 1986 K2500 Suburban was medium gold with a bright blue interior. </div></div>

LMAO. Point well taken.
I trust you made it home with no further adventures. See ya next year.

Dave

[njsteve]

BTW, is that you in the photo cleaning your car, clad in that classic, yellow, tennis outfit with the calf high socks ???

[Tommy]

When you own a 6.5 Turbo Diesel you are often faced with enormous trials and tribulations... I know, I own one as well and mine is down &quot;AGAIN&quot; right now <<GRAEMLIN_URL>>/dunno.gif.. You could send it out to Montana for a professional Cummins engine install. I don't know what they charge.

http://www.autoworldmt.com/Page_11.html

http://www.autoworldmt.com/Page_8.html

http://www.autoworldmt.com/

Here's my problem child... a 2000 model that has cost me more in repairs than the initial purchase price.

http://img.photobucket.com/albums/v284/68sschevyII/2012-07-14_11-04-12_826_zpsdf864076.jpg


Tommy <<GRAEMLIN_URL>>/3gears.gif

[Salvatore]

time to buy a new one!

[Material_Boy]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">BTW, is that you in the photo cleaning your car, clad in that classic, yellow, tennis outfit with the calf high socks ??? </div></div>
Nope, not me. My hair had already started to turn grey. LOL. I also would not be wearing a classic yellow tennis outfit with calf high socks. Is that what you Jersey guys wore back in the day? I am home on the computer instead of the office that sometimes blocks the pics. Yep, that's the car. Great times you were clicking off with that car. Great seeing you again after all these years even if it was just for a few minuets back in 1989. Hope things work out on the the Suburban.

Dave

[SmallHurst]

I have a 1984 F350 Dually with a STOUT 460. You can have the truck for cheaper than whatever you need to do to the Sub..... Just sayin!

[njsteve]

I found a local reputable diesel place today. They were a 45 year, family owned GMC truck dealer until the 2008 GM slaughter of small dealers. They are still a GMC truck repair facility for light and med duty trucks and familiar with the 6.5s.

That being said, I pulled the drain plug and there was a lot of coolant at the bottom, under the oil. So it is looking to be a bit more serious than a head gasket, possibly a cracked block or head. And if the coolant ran through the bearings for any length of time, that pretty much points me towards a new engine.

The shop is going to do a compression test and dye test next week to confirm a diagnosis and see exactly where the failure point is. We will then make a decision based on the facts.

Anyone have any experience with the GM part # 88894125, which is the brand new factory long block? They go for around $6K and have a 3 year/100K mile warranty. I am looking for warranty coverage otherwise I'd go with a military takeout. The shop said they have had nothing but trouble with Jasper - he said they had to replace a Jasper Duramax three times on the same job. After that they wouldn't touch a Jasper again

[SuperNovaSS]

I can't imagine the engine ran long if at all with the coolant in it. I say that because you checked the oil after you shut the engine off and it was normal. Then you checked it after it sat and it was high. Also, if the engine ran with the coolant in the oil, it would be milky, not separated. Why are you thinking it is something more serious than a headgasket at this point?


Jason

[njsteve]

Like Oscar the Grouch, I am an eternal pessimist. That way if something goes right, I can only be disappointed by the fortuitous results. <<GRAEMLIN_URL>>/rolleyes.gif

[Xplantdad]

I hope everything works out for the best Steve. <<GRAEMLIN_URL>>/beers.gif

[GMC_Typhoon]

I'd just slap a junkyard motor in it.I mean one that I could hear run.

They are out there for cheap.

[twertsy]

On Ebay (http://www.ebay.com/itm/CUMMINS-6-B-5-9-TURBO-12-V-DIESEL-1997-DODGE-TRUCK-ENGINE-1991-FORD-95-96-97-94/350943571593?_trksid=p2045573.m2102&amp;_trkparms=aid% 3D555012%26algo%3DPW.MBE%26ao%3D1%26asc%3D298%26me id%3D3111929841800182877%26pid%3D100034%26prg%3D10 79%26rk%3D7%26rkt%3D8%26sd%3D131044707215%26)

[njsteve]

I checked into the Cummins update. Too much labor and modifications needed, like a mandatory 3&quot; body lift it to clear the oil pan, rewiring the truck, computers, etc.

Oh, and I nearly forgot to mention...all said and done, the conversion is almost double the price of a brand new 6.5 Am General 6.5 (GM actually sells the AmGen updated 6.5 that are used in Humvees as their replacement crate engine.) The crate engine dealer that was at MCACN ran my VIN and got me the proper part number for the new longblock assembly, and they seem to be available for around $6,300.

As for junkyard engines, not even the rebuilders use the cores any more because 90% of them have internal stress cracks in the heads and main webs. That is why AM Gen reverse engineered the block and made their own version.

[Norwood]

Id still drop a Big Block in it......

[Tommy]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">As for junkyard engines, not even the rebuilders use the cores any more because 90% of them have internal stress cracks in the heads and main webs. That is why AM Gen reverse engineered the block and made their own version. </div></div>

You were told correct. No junkyard 6.5's....


Tommy <<GRAEMLIN_URL>>/3gears.gif

[njsteve]

Update today. They drained the pan: oil and water in pan was completely separated - no milkshake. They changed the oil &amp; filter and then removed the glow plugs and cranked it and coolant was coming out of several cylinders on both sides. Not a good sign unless it blew both head gaskets simultaneously. The heads come off next week so we should know if it is head gaskets or time for a new engine.

Best price so far for the new AM General 6.5 long block PN 88894125 is $6,362.55 with free shipping and no core charge. 3 year, 100,000 mile warranty from GM. Anyone have a better deal?

P.S. I can't understand why some GM dealers try to charge a core charge when it's a brand new engine and they will not be using the core. I guess it's just a scam because they know you won't waste several hundred dollars to ship an 500 lb long block back, that they will just say is unusable anyway and will then refuse to refund your core $.

[twertsy]

Didn't do a ton of reading on their site but these (http://www.65engine.com/gm_6_5_diesel) appear to be some pretty good prices.....

[John]

.... You might want to check this out....

1996 K2500 with low miles (http://tampa.craigslist.org/pnl/cto/4230547028.html)

..... <<GRAEMLIN_URL>>/beers.gif

[njsteve]

I want to stay away from remanufactured engines as they can only use the existing (and risky) cores out there. To add to that risk is the fact that the vast majority of &quot;new&quot; blocks and heads that these rebuilders use, are counterfeits of the AmGen block, cast in China and are notoriously failure prone.

Plus if you google that company in NY, you get a nightmare of bad rebuild stories and un-honored warranties...

[twertsy]

Well Steve, certainly sounds like you don't need anymore nightmares! Best of luck with the swap! BTW, love the stories on your cars. Unbelievable historical data on all of them, it's a joy to read.

[njsteve]

Thanks for the morale support <<GRAEMLIN_URL>>/biggthumpup.gif

I keep accidentally leaving the TV on Overhauling episodes, as a hint to my kids to call Chip Foose. But so far they haven't taken the bait.

[twertsy]

My 67 bird which I have had since I was 15 in '82 could use some &quot;Foose Love&quot; as well. I'll get to her someday....

[njsteve]

Driver's side head is off and the head gasket is blown out right at the back by the coolant passage, in the regular spot where the 6.5's tend to blow them out. The other head is coming off today or tomorrow. The diesel tech was quite complimentary on how clean the inside of the engine was from 18 years of frequent oil changes.

He also noted how clean the #7 cylinder was from the brief amount of time the water was steam-cleaning the chamber - it removed any carbon residue. The bores all looked nice with the cross hatching still very evident in the cylinder walls.

http://www.yenko.net/ubbthreads/pics/usergals/2013/12/full-1359-8478-hg7.jpg

http://www.yenko.net/ubbthreads/pics/usergals/2013/12/full-1359-8479-hg5.jpg

http://www.yenko.net/ubbthreads/pics/usergals/2013/12/full-1359-8480-hg8.jpg

http://www.yenko.net/ubbthreads/pics/usergals/2013/12/full-1359-8481-hg6.jpg

[twertsy]

Looking good so far. You may get away with this one cheap!

[njsteve]

The passenger side head was removed and head gasket was OK. The diesel tech said that the coolant was only coming out of the driver's side rear cylinder. So they are replacing both head gaskets, head bolts sets, water pump, (since it's the original one), etc., and reassembling everything. Might be back on the road next week. (Fingers crossed)

[Salvatore]

Good job! Put the old girl on Craigslist and buy a new one with a warranty. They are much better. easier on the wallet for repairs too.

[Material_Boy]

Hey Steve,

Glad the direction of this ordeal finally went to your favor, and I am sure you are too. Now drive that sucker for another 15 years, but don't paint it or touch it in any way other than normal maintenance. How many people do you know that tow their original unrestored survivor Firebird with their original unrestored survivor Suburban? LOL. Glad it worked out for ya.

Dave

[luzl78]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">The passenger side head was removed and head gasket was OK. The diesel tech said that the coolant was only coming out of the driver's side rear cylinder. So they are replacing both head gaskets, head bolts sets, water pump, (since it's the original one), etc., and reassembling everything. Might be back on the road next week. (Fingers crossed) </div></div>you're not redoing the heads or at least truing them up?

[njsteve]

The shop is actually an authorized GM medium duty repair center and they have been working on 6.5s for several decades so I have been following their advice. They verified that the heads were flat and good to go. They were rather amazed at the condition of the heads and the inside of the engine in general. Their advice was essentially: yeah, you could spend several thousand on new heads but you won't see much of an improvement in performance or reliability so why spend the extra money. Especially since the engine wasn't run and overheated from the blown head gasket, it was shut down immediately.

In addition to the new head gaskets and new head bolts, we are putting on a new water pump, vacuum pump, 2-1/2&quot; crossover exhaust manifold pipe, and one new valve cover. The valve covers have no gaskets and use only silicone sealer - if the flange is bent from prying it off, replace it, especially if it is on the turbo side because it is no fun to chase oil leaks under all that turbo hardware. All the parts being replaced are the original 1995 components so after 18 years they deserve a break.

[njsteve]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: [email protected]</div><div class="ubbcode-body">Good job! Put the old girl on Craigslist and buy a new one with a warranty. They are much better. easier on the wallet for repairs too. </div></div>

I am happy to accept donations for a new $60K diesel truck in case you're offering. <<GRAEMLIN_URL>>/grin.gif

Since &quot;Babe, the Big Blue Ox&quot; is a member of the family we will keep her another 18 years or so.

[njsteve]

She lives! I stopped by the diesel place this afternoon and they had already got her back together and they were test driving, and checking for any initial leaks, etc. Another day or two to verify everything is up to spec and then I get her back!
(after I pay the bill of course... <<GRAEMLIN_URL>>/rolleyes.gif )

[Salvatore]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body"><div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: [email protected]</div><div class="ubbcode-body">Good job! Put the old girl on Craigslist and buy a new one with a warranty. They are much better. easier on the wallet for repairs too. </div></div>

I am happy to accept donations for a new $60K diesel truck in case you're offering. <<GRAEMLIN_URL>>/grin.gif

Since &quot;Babe, the Big Blue Ox&quot; is a member of the family we will keep her another 18 years or so.</div></div>
OK Steve. Good luck with the old girl. Hopefully no rust will creep up.

[Ryan1969Chevelle]

Back in action.

Good stuff.

Ryan

[67 442]

Sounds like luck is with you Steve.

[njsteve]

The jury is still out on that one until after I see the actual repair bill!

[njsteve]

I was rummaging through the file I have on my truck and found my original window sticker from when I bought her new, back in '95. I ordered the truck with 3.73s but for some stupid reason the dealer changed it to 4.10s without my permission. The fuel mileage would have been a lot better with the 3.73s...

http://www.yenko.net/ubbthreads/pics/usergals/2013/12/full-1359-8560-suburban_window_sticker.jpg

[kwhizz]

When did they stop putting the Diesels in Suburbans...........That's what I wanted when I ordered my DuraMax pick-up in 2006.......the Salesman told me they didn't offer the Diesel option in Suburbans because the engines didn't make enough heat to keep the interior of the Suburban warm in the winter???

[njsteve]

When the Suburban got remodeled in 2000 was when they dropped the diesel engine option. It had nothing to do with heat (that sounds like a typical salesman response, though <<GRAEMLIN_URL>>/grin.gif ) It was about the new Duramax 6.6 and Allison transmission not fitting the floorboard architecture of the new Suburbans.

The 6.5 Detroit Diesel in my truck used the 4L80E heavy duty 4 speed trans.

[67 442]

And how does it Run?

[njsteve]

Just got her back this afternoon. She runs great. Final bill was $3,400. Of that $1100 was for parts - head gaskets, 34 head bolts at $7 apiece, new waterpump (which was the most expensive part) and assorted hoses, serpentine belt, thermostat, gaskets, etc. Since this is a GM repair center all the parts were at list price. But if something goes bad, they cover the part and the labor to remove and reinstall. All in all, I got away reasonably cheaply considering a new engine would have added about $6400 more to that amount.

Before it could leave the dealer, the 80+ year-old owner had to test drive the truck. He has been running the dealership for the last 56 years and nothing leaves without him first approving the work. <<GRAEMLIN_URL>>/biggthumpup.gif

In case anyone needs some diesel work done, here is a link to their place:
http://www.colonialmotorsofnj.com/Auto-Repair-Services-Branchburg-NJ.html

[Xplantdad]

Great to hear that it all worked out for you Steve! <<GRAEMLIN_URL>>/beers.gif

[Ryan1969Chevelle]

Sounds like a really good place to send business.

Glad it worked out without the additional 7K

Ryan

[Bill Rose]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">
In case anyone needs some diesel work done, here is a link to their place:
http://www.colonialmotorsofnj.com/Auto-Repair-Services-Branchburg-NJ.html
</div></div>

Good to know they're trust worthy Steve. Thats not far from here. I've driven past that place many times.

[Alss]

I tried to buy a new truck from them in 07. Would not budge on the price snd not except a GM supplier discount coupon. Then would not trade the truck to the other dealer down the highway who would. Wound up buying a different truck from the 2 nd dealer. Maybe this is why they only fix and not sale new trucks.

[luzl78]

They were probably part of gm bankruptcy restructuring

[Chevy454]

<div class="ubbcode-block"><div class="ubbcode-header">Originally Posted By: njsteve</div><div class="ubbcode-body">When the Suburban got remodeled in 2000 was when they dropped the diesel engine option. It had nothing to do with heat (that sounds like a typical salesman response, though <<GRAEMLIN_URL>>/grin.gif ) It was about the new Duramax 6.6 and Allison transmission not fitting the floorboard architecture of the new Suburbans.

The 6.5 Detroit Diesel in my truck used the 4L80E heavy duty 4 speed trans. </div></div>
The Dmax/Ally fits fine, it's the intercooler that is the issue...it's a popular swap among GM/Duramax enthusiasts, and most simply go with a 2 inch &quot;reverse rake&quot; body lift for the extra intercooler clearance or a few have gone with a custom shorter intercooler, but the engine/trans will clear, and everything bolts/wires up pretty straight forward [good thing about the GMs]...DuraBurb converts several a year, as do several guys over at Dieselplace. There's finally starting to be a few guys using the Dmax/4L85e combo out of the vans, which I always thought would be the way to go for a Suburban anyway...still plenty of hp/tq but better economy because of the more conservative tune and less hp robbing trans...the 8.1L/4l85e was a good combo in the Suburban minus the fuel mileage, but the Dmax would help that.

[Material_Boy]

Steve,

Glad to hear it was a lighter hit to the wallet than you originally thought.

[SuperNovaSS]

Steve,

This is awesome news. It sounds like you are happy you went with the shop that you did. Piece of mind means a lot. If you devide this head gasket &quot;maintenance&quot; up over the life of the truck you are doing great.

I'm happy for you and ol blue,

Jason

[njsteve]

Yeah, the repair cost was only 10% of the original sticker price of the truck (before the 10% website coupon discount they gave me).
<<GRAEMLIN_URL>>/grin.gif

[Tommy]

Steve, had you already moved your PMD out from under the intake? I relocated mine to the top side of the intake with a heat sink to get a little more life from the PMD but they still don't last forever. Glad your back on the road again. <<GRAEMLIN_URL>>/burnout.gif


Tommy <<GRAEMLIN_URL>>/3gears.gif

[njsteve]

Relocated it long ago. I actually have it mounted behind the front bumper, inside the air intake duct so it is getting cool air when the truck is moving.

[njsteve]

BTW, anyone have a nice used rear bumper for a 1993-2000 Chevy/GMC truck? I just noticed mine has a rust hole starting near the tag light. A new GM piece is crazy expensive (PN 15025375) and everyone says the aftermarket ones are too thin and the mounting holes are wrong. A nice used one would be fine.

(I already ordered new floor mats as a Christmas present for the truck...) <<GRAEMLIN_URL>>/grin.gif

[Salvatore]

Aftermarkets are not to bad. i think the GM ones are around $350.00 but they fit real well.

[njsteve]

Now that the truck has been reincarnated with the new head gaskets, I have been showering it with gifts. She does drive so much nicer now and gets better mileage, too!

I replaced the set of Interstate batteries the day before our temps fell to -7 degrees here, last week. When you own something so long you lose track of time. Turns out that the two batteries lasted 7-1/2 years and were only rated for 6 years. They definitely make a difference on a diesel, where you have to have two batteries due to the 20 to 1 compression ratio. she sure spins over fast and starts on the first crank, now.

I also upgraded to the 1997-2000 &quot;K47&quot; High Capacity air box which uses the giant tubular filter instead of the flat panel model air box on the earlier models. Since a diesel operates on an unmetered air supply, it needs all the air possible at all times. Only the fuel is metered. They also require cold air from the front end of the truck via the inner fender ducting, and no hot under-hood air.

Here is the original, restrictive, flat panel filter box found on the 1993-96 6.5 diesels:

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8892-p1010983.jpg

I was able to find the correct K47 air box set up from a 1998 6.5 Diesel GMC 3500 dump truck in a local junkyard. The diesel K47 set up is a unique component and nothing interchanges with air boxes on the gas-engine trucks of that era. It cost me $40 which was a bargain since the air boxes normally trade in the $150 range.

Here is what it looks like:

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8893-p1010979.jpg

The crazy looking 2&quot; tubing is just a noise reduction tube.

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8894-p1010973.jpg

The big problem I ran into was that the unique piece of ABS plastic tubing that inserts into the air filter and mounts into the turbo rubber bellows was mangled beyond repair. It seems that whoever bought the turbo off that 1998 dump truck removed it with an axe instead of simply unscrewing the hose clamp that retained it. <<GRAEMLIN_URL>>/mad.gif

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8895-p1010976.jpg

I did have to order the air box mounting bracket from GM. That piece cost me around $60. It is a rather unique piece and has two studs attached to it that lock into the two grommets that are in the bottom of the air box base (which BTW are discontinued from GM so I found two perfect replacement grommets for $2 in the hardware aisle at Lowes).

Got the air box installed today. I had to improvise a bit and it actually worked out better than finding the correct GM duct piece. I went to the plumping aisle at my local Lowes and bought a 90 degree, 3&quot; inner diameter, PVC elbow for $4. One end fit perfectly in the new air filter element. As for the turbo bellows end, in order to keep the positive battery cable bolt from rubbing on the &quot;new&quot; duct, I mounted one end of the elbow in a vice and used my heat gun to heat up. I was able to then squeeze one end into an oval to match the bellows and also clear the battery bolt. I imagine it also flows a helluva lot better than the original piece that necks down from a round 3&quot; intake to an oval 2&quot; wide exit.

Here is the final result:

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8896-p1010992.jpg

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8898-k47_airbox_.jpg

http://www.yenko.net/ubbthreads/pics/usergals/2014/01/full-1359-8900-p1010993.jpg

[njsteve]

BTW, for anyone looking for a &quot;K47&quot; High Capacity Air Box, I'll let you in on a secret... <<GRAEMLIN_URL>>/naughty.gif

The only difference between the standard air box found on every 1997 to 2000 6.5 diesel and the extra cost, optional K47 was the paper element itself. All the plastic pieces were the same. If you paid the extra $50+ for the &quot;K47&quot; option back in the day, all you got was an extra-restrictive, air filter element with a foam outer cover recommended for hi-dust environments only. <<GRAEMLIN_URL>>/grin.gif

[luzl78]

Steve, why didn't you stick with interstate batteries?

[SuperNovaSS]

That's what I was thinking. They served you so well!


Jason

[njsteve]

Didn't have a local guy anymore who dealt in them and I needed them in stock, ASAP.

[njsteve]

I found a really nice used bumper on Craigslist for $120. It came off a 1996 Tahoe. I spent the week descaling the back of it and then painted the back side with POR15. Those things a really heavy! The mounting bracketry is welded to the bumper core. No wonder they are so expensive. After getting it all ready I then removed the original bumper off the Suburban. Planned obsolescence by GM created a nice area behind the licence plate mounting point that is unwashable and unreachable with a hose, so they just start rustng internally from day one.

I also spent last weekend replacing the tranmsission cooler lines, which, Iike the factory steel and rubber oil cooler lines, leak fluid at the crimp joints where the steel and rubber lines meet. BTW, Dorman makes better replacement trans and oil cooler lines than the AC/Delco lines, which leak after only a few months. They are also held in with those crazy little, wire C-clips.

So now every steel line that was rusty or could rust in the near future has been replaced: brakes, fuel, oil cooler, and transmission cooler.

Next week I install the last of the gifts: a new Diamond Eye high flow exhaust with a 3&quot; turbo down pipe and 4 inch exhaust and muffler. This is the system that all the 6.5 guys use. Got it from Summit Racing with free shipping. According to the guys who have installed the system, it's good for an extra 1 mile per gallon. When your'e getting 14.5 mpg, every little bit helps. <<GRAEMLIN_URL>>/grin.gif

[njsteve]

Installed the DiamondEye 4&quot; exhaust with muffler today. Got it from Summit for $259.97 with free shipping. Went in surpisingly easy. Hardest part was getting the clamp ring on the turbo. That took 45 minutes of finagling with two of us groping around above and below the truck (on a lift, of course). Sounds great and feels a little bit peppier than it did with the factory installed, crimped 2-1/2&quot; downpipe and a 3&quot; muffler and tailpipe.

All the hanger clamps lined up correctly when we put the trimmed to fit, straight pipe ahead of the muffler instead of behind as pictured in the not-so-detailed diagram.

Took around three hours to install. Finished just in time to drive home in yet another snow storm.
<<GRAEMLIN_URL>>/rolleyes.gif