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Reviving a 93

28K views 233 replies 26 participants last post by  56pan 
#1 ·
Today I finally got around to getting my 93 K2500HD back in the shop. It has been sitting for well over a year[maybe 2?] since I worked on it last.:eek: I had bought this truck as non-running that was making very bad knocking sound . The PO had started taking it apart and then threw in the towel and let it sit for a year or 2.
Shortly after I bought it , I got it running with the crossover exhaust pipe removed. It did have a very terrible knock that I could easily hear over the very loud exhaust. It did still have good oil pressure, so there was still some hope but I was going to pull the engine out to really check it out.
It turned out the bad knock was mostly the broken flexplate.:idea: As long as the engine was out and on a stand, I figured there was no better time to put in new head gaskets, ARP studs, timing chain and reseal the whole engine.
After pulling the heads off I found divits in the pistons from running with very bad injectors and rust in 1 cylinder from either a leaky head gasket or from sitting with no exhaust and a valve open. I pulled that rod and piston out, honed the cylinder and put new rings only on that piston.
I put it back together with Fel-Pro head gaskets, ARP head studs, Cloyes timing set, new valve seals, 97 HO water pump and a new set of "Medallion" injectors from Accurate Diesel. I cleaned it all up good and painted it Alpine Green which is better known as Detroit Diesel Green.
I cleaned up the engine compartment and painted it also. I put in Energy Suspension Poly engine and transfer case mounts and bought a oil cooler line set from Lubrication Specialist.
I put the engine in and got it running but it ran terrible. It wouldn't rev and there was lots of blue smoke. Apparently the injection pump went bad from sitting so long. :banghead::banghead: I didn't have a spare IP at the time and other things came up so the truck got pushed outside and ignored.:whistle:
Now with the frame on my 92 getting close to :eek::eek:dangerous, I need another truck running ,so this 93 got the call today. I'll be swapping a used 4911 IP on it, making some new battery cables for it and more than likely doing rear brakes and new steel lines since the rear reservoir was empty when i looked in it today.
Today was just getting it in the shop and start cleaning and looking over what else will need to be done to get it drivable.
I will do a separate thread on building battery cables. I've bought the tools and supplies to make my own since I have so many trucks and other equipment .
 

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#228 ·
Most times I end up taking the manifolds off because the OE bolts or studs break off. I weld a nut to the broke off bolt and heat the manifold red hot before trying to turn them out. Most times I have to repeat the nut welding and heating. I've tried drilling but it never worked. When I put it back together, I run a thread chase in the threads and use a2 stainless steel bolts with anti-seize compound on them.
 
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#229 ·
I had one of the driver's side bolts crossover bolts frozen in my '93. Disclaimer: I will not be held responsible if you burn your truck to the ground. I packed wet rags in the area, used a small tip on my acet. torch and small flame. Took a while, but I heated the head of the bolt red hot for about a minute. Must have cracked the rust, because it broke free after that.
 
#230 ·
Yes, heat is the gift that says " I'm not asking you to come off anymore" :cool::p
You do have to be watchful and use plenty of heat but those stubborn bolts will let loose
 
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#231 ·
Soak soak and soak again with penetrant. PB blaster. Or wd40 penetration spray. I spray leave for a day come back and heat with a torch (not even glowing) and immediately hit it with more spray. Let it cool. And spray with PB again. Next day it always comes off.

Note a minimum of an hour is needed for a penetrant to work. None of this is instantaneous
 
#232 ·
PB is definitely a good product along with seafoam deep creep.That stuff works awesome as well.
 
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#234 ·
It worked for me. You have to be very careful and the wet rags kept the heat from lighting anything on fire. I wasn't about to pull the manifold. _SMALL_tip on the acetylene torch. Not a rosebud.
 
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