New Guys Read--> Reliability/Mod List!

[Pruittx2]

6.5 Diesel owners

List of Things to make it Reliable

1) Relocate PMD Outside of Engine compartment on HeatSink
2) Pull Radiator, to clean in between All coolers, Use Only AC-Delco t-stats
3) New oil cooler lines with real plumbing
4) AC-Delco ONLY OPS W/Relay Mod for OPS reliability (on years needed)
5) Fuel Pressure gauge to keep tabs on Lift pump, fuel filtering issues
6) Battery cable fix, using Bolts&Nuts & Adding #4 wire from Alt to + terminal
7) Pull and clean ALL grounds!!

List of Mod's to get the most out of your rig

1) 4" exhaust with 2.25" or 2.5" crossover
2) Boost and EGT Gauges
3) Manual Wastegate Controller
4) 97+ Air Cleaner Assem or better
5) H/O Water Pump, Duramax Composite Fan with a H/D Fan Clutch or fan clutch Mod
6) Performance chip for more fuel, better idle, More Fun!
7) Feed The Beast Mod
8) Bosch Duraterm or ACDelco 60G Glowplugs with GlowPlug Override Mod
9) Known good injectors, if you don't know Test/Replace them! Bosch or Delphi
10) 1993 Lift Pump or better H/D unit ie Walbro or others

11) Then we can look to add bigger turbo's Att or Holset,
Water/Meth or Propane injection systems,
air to air or water to air InterCoolers, ect.

The explanation, and expansion of info on any or all of these mod's can me found here:
http://www.dieselplace.com/forum/showthread.php?t=53309


I'm sure others can comment on a few other things, that should be on this list.
But for new members thinking of getting all they can out of there rig, This should about do it.
Guys that are pulling 20,000+Lbs here, have these if not more mods.


Now start saving that coin, and get busy!

 

[Matt Bachand]

Battery cable fix and clean all grounds should be up around the top IMO. Nice work, and good idea.

FREE MODS.

Clean ALL Grounds (Remove/wire brush/re-install)
Battery Cable Mod
DIY Fan Clutch Mod (Adjusts fan clutch to engage sooner)
Clean Radiator

Very heat sensitive engines. Don't push them hard over 210, your fan clutch should be engaging at or around 210 IMO,

THE 260 Danger Zone on your Factory Gauge is MISLEADING!

Red should be at 220 tops. With 210 being top of comfort zone. Your Fan should be HOWLING the air at this point. If its not, Check out the DIY Fan clutch Mod thread.

http://www.thetruckstop.us/forum/showthread.php?t=12265&highlight=fan+clutch+mod

 

[JiFaire]

Great idea, guys! This thread is now under M for Modifications in the 6.5 Technical Reference Library!

 

[TurboTahoe]

What years need the OPS Relay Mod and why?

-Rob

 

[NVW]

What years need the OPS Relay Mod and why?

-Rob

Should just be OBD1, OBD2 runs the LP via ecm.

 

[Pruittx2]

Wo-Hoo,,, I finally made it in the Stickies!!!
:hurray: :hail: :notworthy: :cool2:

After almost 3 years, with my truck, going through what others, are getting ready to do,, I thought this would be handy for others.

Thanx Jim!

 

[JiFaire]

Wo-Hoo,,, I finally made it in the Stickies!!!
:hurray: :hail: :notworthy: :cool2:

After almost 3 years, with my truck, going through what others, are getting ready to do,, I thought this would be handy for others.

Thanx Jim!

You're welcome, but don't thank me.. thank YOU. This is a Member's site; I can build all the stickies, but it's a lot more fitting that the members do it. Look at the Tech library - every entry is referenced to one of you guys.

So like I said, thank YOU!

 

[WarWagon]

Check radiator for plugged tubes on the inside.

Replace old radiator hoses, heater hoses, and the water pump bypass hose.

Do not go past 215 ECT. Unless you want to replace the heads etc.

Other cooling options like a 9 blade steel 20” fan and a low kick on temp fan clutch from Kennedy diesel or mod your own HD fan clutch is also a good choice with a 180 t-stat. The OEM fan clutch is risking your engine as they didn’t hold very well even when new. Clutches wear out after 5 years, by losing 200 RPM per year, so it is best to just replace it. 20” fans clear the shroud no questions asked.

AC Delco 60G’s are junk. After looking at the 5 burned up ones of mine I do not believe they are self regulating. Burned the case off 1 and the other 4 were 2/3 – 1/2 completely gone.

Cheat for a quick pyrometer install is to put the probe in the crossover pipe. Ideal is below the turbo, but, when time limits you get it done by using the crossover pipe.

 

[Paveltolz]

Excelent Post. Congrats on making it to the stickies Dave. Once you can snatch the injector from JiFaire's hand, you can be a moderator!:thumbsup:


FWIW, When I got my truck home, I knew there were a lot of issues to address and "wants" to control. Truck hadn't been serviced lately so confidence in the 'known fail' areas were of concern. FSD on the intake and a long with an ignorant new owner. Some items needed to be addressed immediately, the 'wants' could wait but patience is a hard thing to master. There was so much that I was very aware that I would soon be running in circles so, I made up a prioritized list to stay focused.

Priorities of Work:
1. Safety
2. Preventative Maintenance
3. Performance/comfort (improvement, not “tuning”)
4. Cosmetics

Number one issues were brakes, ball, joints, alignment etc.
#2 = Coolant, Tranny, Lubrication flushes and upgrades; Replaced Injectors and Glow Plugs, LP, OPS, FSD (relocate); clean grounds,Bed liner, clean radiator and then there's the HO Waterpump and Fan upgrades still to come.
#3 = Exhaust, PCM,
#4 = Lift, Rims, Tires, Paint and the like.

Paul

 

[saturntech95]

Wow I geuss I did pretty good building my truck then.

 

[bison]

Fuel pressure gauge. It should top the list IMO

Oops, i see it is in there :thumbsup:

 

[Brooklyn Tow]

Exhaust should be one of the top mods....right up there with the PMD.

 

[bison]

Exhaust should be one of the top mods....right up there with the PMD.

I beg to differ.

IP and PMD will live long time with good fuel flow/pressure.
Fuel gauge will let you know if fuel flow/pressure is compromised ie bad OPS/LP/filter.

 

[Brooklyn Tow]

I beg to differ.

IP and PMD will live long time with good fuel flow/pressure.
Fuel gauge will let you know if fuel flow/pressure is compromised ie bad OPS/LP/filter.

That is your right.

 

[buddy]

Yeah, exhaust is a good mod, improves both performance and efficiency, however reliability mods trump that

 

[Matt Bachand]

Yeah, exhaust is a good mod, improves both performance and efficiency, however reliability mods trump that

Do em both........

I love the fuel pressure gauge. Just to always see whats available at the IP is great.

It sure caught my buggered Walbro. I'd probably still be driving with it dead otherwise

 

[great white]

I would say the egt gauge should be in the first round of modifications also.

High EGT's will roast an engine (apparently, especially a 6.5) if you don't know about it and indicates the need to investigate other cause factors. Those reasons make an EGT guage high on the durability and longevity scale.

I know I would be happily jamming the go pedal, oblivious to soaring ptit's, without one....

Inspect and replace harmonic damper/lower pulley if necessary should also be in the first round. All of these old trucks are pretty well past the 100,000 mile mark by now and there's lots of stories about failed dampers and cracked blocks/broken cranks...

 

[Pillow]

Inspect and replace harmonic damper/lower pulley

100% agree there!

1. PMD
2. Exhaust

Pyro BEFORE any performance chips are added. Plus a boost gauge, they are cheap.

Pyro if you tow even stock... IMO Pyros should be mandatory on any diesel.

 

[Pepperidge]

Closed at the request of the original poster