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Dodge Trucks => DIY & Self Help => Cummins DIY's => Topic started by: 04cumminsram on December 14, 2009, 06:06:00 am

Title: In Frame Overhaul
Post by: 04cumminsram on December 14, 2009, 06:06:00 am
OK, I have a customer that had a problem of oil consumption and slight loss of power... 2006 Cummins with 80k pretty much stock other that a edge juice with attitude.
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172310.jpg)

Truck had serious blowby issues so i told him he more than likely had a broken ring, He got the money together and came to the shop and 830 am saturday morning, the truck on a trailer so by 9am im elbow deep in this venture...

well i started to take some pics of the job and there are DIy's on here to remove injectors

http://www.dodgeownerforums.com/smf/index.php?topic=2461.0 (http://www.dodgeownerforums.com/smf/index.php?topic=2461.0)

after you get the valve cover off and coolant and oil drained your ready to rock
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12102631.jpg)
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12102612.jpg)

Remove the 26 head bolts, disconnect the Downpipe and Injector Rail feed line on drivers side along with wiring harness's. The Injector return line is on the rear of the head i have no pic to show it because you can barely get your hand and a 3/4 wrench back there let alone the Droid to get a pic...sorry

I pulled the head with the turbo and manifold still on, easier this way in my opinion... you should end up with something like this

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12142241.jpg)

now you loosen the motor mounts and pic the engine up as high as you can get it, almost 4 inches you have to go to remove the Oil pan. then you will see this

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12142311.jpg)

You have to remove the oil pickup and block stiffner plate and you will see this

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172427.jpg)

Now you can remove the rods and pistons, I barred the engine over till each one was at the bottom to make it easier to get to the bolts, and then push the pistons up through the top.  You may find yourself having issues getting them out, so push them back down and hone the top of the cylinder a minimal amount to remove any debris at the top of the cylinders

when you get the pistons out it should look like this
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172349.jpg)
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172320.jpg)

Now is the time to Remind yourself CLEANLINESS IS THE KEY... Take your time and clean everything

I used my expanding hone to clean the cylinder walls up then sprayed everything down with solvent and blew dry then repeated

now with everything out you can inspect everything and this is what i found

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12151111.jpg)
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12151119.jpg)

Number 1 and 6 the top rings were cracked, luckily the cylinder walls were not tore up so a mimimal amount of honing was performed... Before Honing remove the bottom oilers that shoot up into the bottom of the pistons...

now clean all of the components

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172254.jpg)
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12172301.jpg)

install new rings and upper and lower bearings REMEMBER never touch the bearing surface that will contact the crank, i wear gloves and use some kind of assembly lube when putting all back together.

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12181343.jpg)

now put pistons back in the same hole they came out of

(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12204412.jpg)
(http://i239.photobucket.com/albums/ff207/04cumminsram/in%20frame/2009-12-12204421.jpg)

torque the rods to spec

I also removed 3 of the main caps to make sure the mains were not bad, and reinstalled and retorqed the caps.

now you reinstall the head and hook it all back up

sorry for such few pics, there are more here http://s239.photobucket.com/albums/ff207/04cumminsram/in%20frame/ (http://s239.photobucket.com/albums/ff207/04cumminsram/in%20frame/)

but it ran at 145am sunday morning... !  :up:
Title: Re: In Frame Overhaul
Post by: ChinookFE on December 14, 2009, 07:47:33 am
Awesome Man.  I'd never try it myself, but its always cool to see the stuff inside you never get to see.
Title: Re: In Frame Overhaul
Post by: Cujo on December 14, 2009, 01:45:41 pm
Well Damn, someone was busy this weekend. Nice job. Any idea why the rings cracked?
Title: Re: In Frame Overhaul
Post by: 04cumminsram on December 14, 2009, 02:10:01 pm
im gonna say heat did it, its ran like this since he bought it, its his first Cummins...


also did a CP3 on a 6.7l and gauges Friday night...lol
Title: Re: In Frame Overhaul
Post by: ERT on December 14, 2009, 02:47:44 pm
 :eek: Damn good time on that  :up:. He's still under his diesel warranty though, why didn't he take it too the dealer?


Title: Re: In Frame Overhaul
Post by: 04cumminsram on December 15, 2009, 02:18:01 am
:eek: Damn good time on that  :up:. He's still under his diesel warranty though, why didn't he take it too the dealer?




Well the dealers around here blow large donkey balls... They never looked at the truck when he bought it and it was 1.5 gal low on oil and had the edge and a k&n drop in filter... they told him that his warranty was void because of the edge... The dealer installed it for the previous owner, they told him to put a stock air cleaner in and run it for a month and they would take pics blah blah blah and then after that they told him to get bent because it had a "chip" on it...lol oh well
Title: Re: In Frame Overhaul
Post by: ERT on December 15, 2009, 03:40:38 am
Yeah, some dealers really blow and give us all a bad name   :banging:

Oh well, at least he got it fixed  :up:
Title: Re: In Frame Overhaul
Post by: Kilch123 on December 15, 2009, 03:43:33 am
Good Job Adam!
Title: Re: In Frame Overhaul
Post by: 04cumminsram on December 15, 2009, 05:19:38 am
thank you sir !
Title: Re: In Frame Overhaul
Post by: dragonslayer169 on December 15, 2009, 06:35:41 am
Wow, that's impressive, good job man. That is some dedication to get it done in one day. I would have figured it would be a min 2 day job.
Title: Re: In Frame Overhaul
Post by: 04cumminsram on December 16, 2009, 12:29:59 am
thanks... it would have went quicker but i spent a couple hours searching for a part and then had to eat and things but yea i was impressed


One of the tech's how long does this take Book Time?  ::?:
Title: Re: In Frame Overhaul
Post by: ERT on December 16, 2009, 01:25:44 am
Book time = 14.3 hours

For all rings, hone cylinder walls and replace rod bearings.



 :cheers:
Title: Re: In Frame Overhaul
Post by: biged681985 on December 16, 2009, 03:42:23 pm
nice job adam
Title: Re: In Frame Overhaul
Post by: 1SlowFormula on December 16, 2009, 07:16:52 pm
Nice work, and doing it in a little more than 16 hours including stopping to eat and keeping things clean is great work. Now the question, was that your first time that deep into one of these motors? If so that is even more impressive...

I have rebuilt gas motors in a weekend before but that included 1/2 a day for removal and reinstall, never while it was in the vehicle, my hat's off to you on that one...
Title: Re: In Frame Overhaul
Post by: mayfair on December 17, 2009, 12:11:46 am
thanks for the write up !! :cheers:
Title: Re: In Frame Overhaul
Post by: 04cumminsram on December 17, 2009, 12:30:33 am
Nice work, and doing it in a little more than 16 hours including stopping to eat and keeping things clean is great work. Now the question, was that your first time that deep into one of these motors? If so that is even more impressive...

I have rebuilt gas motors in a weekend before but that included 1/2 a day for removal and reinstall, never while it was in the vehicle, my hat's off to you on that one...


no this wasnt my first time, I built the motor in my truck also... although this is the first time for a in frame overhaul

mine started on a couple pallets and a few boxes, at school it took 2 days 7am to 5pm

My School is Wyotech...lol
Title: Re: In Frame Overhaul
Post by: Austin The DieselTech on January 24, 2010, 09:58:30 pm
Great write up.!!!!!!   Lets see ya do one that fast on a 3406E.
Title: Re: In Frame Overhaul
Post by: noplugs on January 24, 2010, 10:36:04 pm
Very impressive. Lets hope that none of us ever need to see it in person...




Unless it is a planned upgrade  :devil2:
Title: Re: In Frame Overhaul
Post by: 04cumminsram on January 24, 2010, 10:44:26 pm
Thanks Rob...

We had 2ndDodges 6.7 out and tore down in less than 4 hours...will take pics of the rebuild though
Title: Re: In Frame Overhaul
Post by: mattd6178 on August 02, 2015, 09:48:57 pm
How do you get the last 3 push rods out? Or do they come out with the head?
Title: Re: In Frame Overhaul
Post by: noplugs on August 03, 2015, 03:50:36 am
How do you get the last 3 push rods out? Or do they come out with the head?

when you take the heat resistant fiber from under the cowl you will find two large rubber plugs that you can remove..
These two holes let you move the pushrods up into the cowl are and out of the block.. its give you 6+ more inches of room to maneuver them out.
Title: Re: In Frame Overhaul
Post by: Patch164 on March 21, 2017, 07:41:09 pm
I realize this is an old tread but I was wondering how you kept the crankshaft and all that clean when you honed the cylinders?? I'm doing this to mine now I had a cracked piston and don't want to pull the whole motor. I know keeping everything clean is my #1 concern.