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took on project for veteran

T

tony.miller

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Location
hartford illinois
I took on a project for a disable Iraq war veteran. He came to me to get his transmission rebuilt. Him nor his wife know I'm doing this. I called them to come pick up the truck when I was done with the transmission. They started it up and drove off. I notice there was some problems when they drove off. I called them and told them there was some problems and asked if they could come back and they did. They left the truck with me. And I have been digging into it. The truck is a 1993 Chevy Silverado ext cab c3500. It has 400,000+ miles. I am a diesel mechanic but for dodge. So I don't know much about the 6.5td. That's why I came here to pick you brains and learn tricks and tips. What mods to give him and to stay away from. I am not charging him for the work I'm doing I'm not charging him for the parts. I wanna give back to him for all he had done. He is 26 years old has two kids and a wife. She can't work because she has to take care of him. This truck means a lot to him. This was the first truck he bought when he got home from Iraq. And I wanna give him the best. I have a company that is gonna do the body work and paint and tinting the windows. All I have to do is put the company's name on a window for advertising.

First problem 2 of the 8 injectors worked properly. Replaced all of them they work fine now.

Second problem the turbo. I wasn't hearing it. It was stuck closed. Freeded it up and can hear it now but there is play in the turbine. Also there is 5 or 6 bolts and lock washer that holds the turbo housing and the turbine together he is missing three of the lock pins. Chevy can't get them they said only way to get them is buy a new turbo for 1500.
 
Third problem truck has major blow by. I did some research and read these engine have a problem with cracking is that true? would it be better to just get a different engine or rebuild.

Forth problem I believe is the ip. When your driving and just let of the gas pedal truck starts to buck. Give it gas and it stops. Wondering what you guys might think it be.
 
As far as the blowby pull the engine and drop the pan to check for cracks they'll be going thru the main bearing bolt holes into the block. if it's uncracked put it back together with gapless rings. as for the IP you need to verify that the LP is working, could be a lack of fuel to the IP
 
^^ I would agree. The 93's are all mechanical injection. Not a whole lot can keep them from running.

Good deal on paying it forward. We need a little more of that in this world.
 
There are plenty of suggestions in the technical library :)

Common mods are:
> Fuel delivery
- Feed the Beast (FTB): increases the fuel delivery from the filter to the IP.
- Remove the in tank 'sock' and install a filter just upstream of the lift pump (LP)
- Lift Pump - Walboro (I forget which one is best for the DB2 (mechanical) injection pump)

> Exhaust flow:
- 3" down pipe (replace the OE pipe), 4" back (recommend a muffler)
- turbo replacement. Here is a suggestion http://www.thetruckstop.us/forum/showthread.php?42735-A-Team-Turbo-with-less-than-5000-miles where the bonus is deleting the vacuum pump (will need a shorter belt).

> Air flow: the high flow filter (round) known by GM's RPO code of K47.

> Oil Pressure Switch (OPS) upgrade to use a relay (do not recall whether this is on the 93 or not, and am sure somebody will correct me if not).


If the motor needs replacement, there are military pulls that are noted as good replacements (will likely need new pistons), or a new Optimizer 6500.


Presuming the goal is to do all the work 'on-the-sly' as a gift, might prove difficult without telling them due to turn-around times on parts delivery.


If you want to try for a 'big-bang' surprise, might consider:
> do the quick triage on whether the motor needs replacement, give the truck back, and mention that the truck seems Ok but you want to look into a few things.
> research how far you want to take the project, gather the parts, 'dry-fit' them in the shop, and then coordinate a time for the Vet to return it for a 'tweak'.

Point is that if it is full-blown motor replacement, it is going to take every bit of (at least) two months to do all the research, gather parts, and dry-fit them; if you have the truck for all this time, it will draw suspicion and you will have to continually cook-up BS reasons on why it is taking so long. If you give it back, source the parts, and coordinate when ready, then the 'apparent down time' is only a few days to a week or so.
 
I just went through the surging issue my self. It was the IP, but check the lift pump. I bought a reman from ssdiesel and they put a new head and other parts in so it is updated and so the IP won't have that issue as easy again. I have a turbo I would donate. I also have a motor from a 1993 that runs good but needs the IP I would donate it to the gentalman. PM me I have a lot of parts and will help out we're I can with the project.
 
For mods. 3 big ones lift pump module, turbo master, gauge set. Just installed my gauge set from glow shift, very nice set came with fuel pressure, boost, egt, and pillar pod. $250. This is a must so he can watch his temps and boost.
 
JayTheCPA said:
There are plenty of suggestions in the technical library :)

Common mods are:
> Fuel delivery
- Feed the Beast (FTB): increases the fuel delivery from the filter to the IP.
- Remove the in tank 'sock' and install a filter just upstream of the lift pump (LP)
- Lift Pump - Walboro (I forget which one is best for the DB2 (mechanical) injection pump)

> Exhaust flow:
- 3" down pipe (replace the OE pipe), 4" back (recommend a muffler)
- turbo replacement. Here is a suggestion http://www.thetruckstop.us/forum/showthread.php?42735-A-Team-Turbo-with-less-than-5000-miles where the bonus is deleting the vacuum pump (will need a shorter belt).

> Air flow: the high flow filter (round) known by GM's RPO code of K47.

> Oil Pressure Switch (OPS) upgrade to use a relay (do not recall whether this is on the 93 or not, and am sure somebody will correct me if not).


If the motor needs replacement, there are military pulls that are noted as good replacements (will likely need new pistons), or a new Optimizer 6500.


Presuming the goal is to do all the work 'on-the-sly' as a gift, might prove difficult without telling them due to turn-around times on parts delivery.


If you want to try for a 'big-bang' surprise, might consider:
> do the quick triage on whether the motor needs replacement, give the truck back, and mention that the truck seems Ok but you want to look into a few things.
> research how far you want to take the project, gather the parts, 'dry-fit' them in the shop, and then coordinate a time for the Vet to return it for a 'tweak'.

Point is that if it is full-blown motor replacement, it is going to take every bit of (at least) two months to do all the research, gather parts, and dry-fit them; if you have the truck for all this time, it will draw suspicion and you will have to continually cook-up BS reasons on why it is taking so long. If you give it back, source the parts, and coordinate when ready, then the 'apparent down time' is only a few days to a week or so.
Click to expand...


Like
 
Bad injectors will cause the IP issues (Bucking) as well as being out of adjustment. You have idle adjustment and timing. Idle is setting it to the sticker and a second setting for cold advance. Then set the TPS to 0.5v or slightly over. The timing chain stretches badly and quickly on these engines.

Walbro FRB-5 is the correct pump to replace the POS factory lift pump on the DB2. Lack of fuel pressure to the IP causes them to run no so great, but, won't wipe the IP out like some Dodge diesels suffer.

Pull and clear codes to see if there are any for the rebuilt transmission. Double check the speed sensor 2 wires to the harness as the insulation falls off the wires and they short. Auto trans oil needs to be changed every 25K.

Check and replace the engine oil cooler hoses.

Replace the fan and fan clutch. Use a 1998 9 blade 6.5TD steel or trim the shroud and use a 21" 2002 Duramax plastic fan. Clutch from 1998 or a Kennedy diesel low temp clutch. High Output water pump off a 1998 is a good idea.
Pull the radiator and send to a shop to be boiled out and repaired. Remove the grille and clean the AC Condenser esp. remove the oil coolers and the mat the builds up there.

Check the harmonic balancer on the front of the engine. One for the belts and the other keeps the crank from snapping. Any rubber looks bad on them replace them. Fluidampr balancer are expensive and available.

A BD spool valve on a A Team Turbo would be a great replacement for a bad stock turbo. More info on how much the stock turbo sucks - and yes, sucks fuel too!
http://maxxtorque.com/dieselcommuni...ods/244-the-65-factory-equipped-asthma-attack
You can get used turbo parts as the GM3 is well hated and replaced often with something better.

Leroydiesel can hook you up for the fuel pump and other items including the ATT turbo kit.

Gapless rings are awesome if the block is crack free.

If it needs an engine due to cracks: Look at a used low mile military surplus 6.2, throw away the 6.2 heads for 6.5 heads. A 6.5 is just a bored out 6.2 with minor head changes. You could even run the 6.2 heads, but not the best...
 
WarWagon said:
You have idle adjustment and timing. Idle is setting it to the sticker and a second setting for cold advance. Then set the TPS to 0.5v or slightly over.

Pull and clear codes to see if there are any for the rebuilt transmission.
Click to expand...

Just checking . . . Does this still hold true for a DB2 IP system?
 
JayTheCPA said:
If you want to try for a 'big-bang' surprise, might consider:
> do the quick triage on whether the motor needs replacement, give the truck back, and mention that the truck seems Ok but you want to look into a few things.
> research how far you want to take the project, gather the parts, 'dry-fit' them in the shop, and then coordinate a time for the Vet to return it for a 'tweak'.

Point is that if it is full-blown motor replacement, it is going to take every bit of (at least) two months to do all the research, gather parts, and dry-fit them; if you have the truck for all this time, it will draw suspicion and you will have to continually cook-up BS reasons on why it is taking so long. If you give it back, source the parts, and coordinate when ready, then the 'apparent down time' is only a few days to a week or so.
Click to expand...

Plus you can schedule a 'Get together' and those who are available and want to help out can drop in and help turn a wrench. Kind of a "Overhaulin" 6.5 style event.

Keeping the engine cool with upgraded waterpump, clutch and fan will help. Plenty of ideas out there on this one. My two motors both got the Heath Kits. Never an issue with heat after that.

If you do go with a manual wastegate control for a GM-X turbo, the gauge kit is a must for monitoring the EGTs as noted by Jay as is the exhaust.

PM sent about parts on my shelf.

Welcome to TTS and thanks for taking care of this Vet. Bless you and your company.
 
If you're going whole hog, the Battery Cable and Glow Plug Wire Kits from Racedaymechanic (PTWiringsolutions.com) are a great addition and he's a site sponsor as well.
 
So the wife called me today about the truck. I asked her to come by and I'll explaine what is going on. I told her I was gonna be doing some work on the truck to make it more reliable. She hit her knees crying. Her husband has been trying to work on this truck for almost 4 years and has had some big dreams for it. I told her I'll need time to work on it and come up with the money and she told me to take as much time as I need. They have another vehicle.

So right now my goal is to do a mild performance/fuel efficient truck. Me and some of my buddy's have chipped in and we have about 1000 dollars right now but that amount will be growing.
 
We need a thread on parts you have and 'donated' parts. Some may wish to remain anonymous. Others could look over their parts collection and 'clean up the garage'.

Some 'before' pictures would be interesting.

What branch of service was the vet in? A sticker on the back window for that would be a nice touch.
 
JayTheCPA said:
Just checking . . . Does this still hold true for a DB2 IP system?
Click to expand...

This is a adjustment procedure for DB2 systems with a 4L80E last year being 1993. The DS4 1994+ is computer control. There are other ways to adjust it requiring special antique tools.
 
What condition is the front end in? Chevy's wear them out often including the rag joint at the steering box to steering wheel.
 
We have a 2002 Duramax fan we can send your way. It is from a Veteran who bought it for his 454 and found out it doesn't fit.
 
The vet was in the army. 2006-2010. He suffers from ptsd (post traumatic stress disorder) tbi(traumatic brain injury) seizures, migraines, bad back, and knees. I will post pictures up the next few days. I'll start up a new thread of parts that are being donated of that we have already bought.
 
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