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6.5L Diesel Engine Discuss the 6.5 GM diesel engine & associated components. Automatic transmission questions & problems belong in the 4L80/85 - 4L60E - 6L90 Transmission Forum

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Old 03-01-2015, 07:42 PM   #1 (permalink)
Cumminsdriver
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6.5 is in the shop...

Well yesterday I drove the old Chevy over to my parents place to put it in dads shop. Gonna let the snow melt off and dry up, then Im pulling the transfer case to find out why it sounds like a machine gun in four wheel drive. Need to check the fluid in the front and rear end's while im in there too.

My cab mounts are also rusted almost completely through. Going to get the old ones out of the way and build new ones so that I can get the cab level with the bed again. I didn't realize they were so bad until I got under it looking around. Im hoping that is the source of most of my vibration that I have in the cab at idle.

Ill try and keep you guys updated with some pictures when I get dug into it, hopefully in the next week or so. I need to get this thing ready to go for a while because I hope to be tearing the head off my dodge and doing the rear main seal at some point soon once the weather gets a little nicer...

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Last edited by Cumminsdriver; 03-01-2015 at 07:44 PM.
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Old 03-01-2015, 07:55 PM   #2 (permalink)
Freddyack
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Sorry you have to go through all this, but looking forward to the transfer case pics and learning what you find out.

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Old 03-01-2015, 09:32 PM   #3 (permalink)
Cumminsdriver
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Yeah I'm not looking forward to it but honestly it shouldn't be terrible

I've done some research and apparently there are some nylon shift fork pads in the t-case that can wear out and cause my exact problem. If that is the issue I shouldn't be out much money, just time. I'm really hoping that's the problem. Either way, an entire rebuild kit is like $80 so hopefully I can get away with not spending too much.

As for the cab mounts, I have a lot of scrap steel, plasma torch, welder etc for resources so I should be good there
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Old 03-02-2015, 08:55 PM   #4 (permalink)
Cumminsdriver
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Anyone know where is the best place to get individual parts or a rebuild kit for the transfer case in this thing?
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1994 Dodge 2500 4x4 reg cab CTD/Auto with some go fast parts

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95 Chevy 6.5 Diesel 2500 4x4 Auto - 129k miles





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Old 03-02-2015, 09:25 PM   #5 (permalink)
Tr00b
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I found radiator mounts at the local ma and pa scrap Yard... Took the battery sawzall to a bare truck frame. Got the front ones for $20 and the rubbers with new bolts at Rock Auto for about the same. Nalley GMC site was helpful for showing which ones I needed. Might be worth your time to see if the scrapyard has a banged up frame you can hack on.
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Old 03-02-2015, 11:06 PM   #6 (permalink)
dieselmike1
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Cumminsdriver, sorry to hear about your transfer case problems. If you put that rebuild kit in, if its not too much trouble, can you take some pics., and an explanation of the procedure. I haven't done a TC, and would be interested in the process. Probably would help a few others too.
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Old 03-03-2015, 12:27 AM   #7 (permalink)
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Quote:
Originally Posted by dieselmike1 View Post
Cumminsdriver, sorry to hear about your transfer case problems. If you put that rebuild kit in, if its not too much trouble, can you take some pics., and an explanation of the procedure. I haven't done a TC, and would be interested in the process. Probably would help a few others too.
Someone posted either pictures or a link to a thread with pictures in Cumminsdriver's initial thread about the problem. I think.
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Old 03-13-2015, 11:54 PM   #8 (permalink)
Cumminsdriver
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Well I finally got a chance to work on the old girl. Went over to my parents where my truck is parked in my dads shop at the moment and me and a buddy tore into it. Really didn't have any issues getting anything out. Both driveshafts came right out and once I jacked up the transmission some, I got the crossmember bushing out that the transmission bolts to which gave me good access to the T-Case nuts. Got it on the bench and pulled it apart until I got to the internals. The verdict is that the chain is totally shot. Very loose, and all of the nylon shift fork pads are worn down to nothing as well. Also, the aluminum range fork is worn down so ill have to replace it. All the bearings, shafts, etc.. still look pretty good. Im going to clean everything up, replace the chain, shift pads, and range fork, and stick it back together with new fluid. I think that will have me back in business and shouldn't cost a terrible amount. I still have no idea where Im getting parts from yet so if anyone has a good source for t-case parts, let me know.

Here's a short video. I thought the slop in the gear/shaft could be an issue but its actually normal.
https://www.youtube.com/watch?v=nKVY5v-gHUI
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2001 Dodge 3500 Ext Cab Dually 4x4 CTD/Auto. Edge Juice CTS, Air Dog, 6" Stacks, 285 Nitto's - Self Built Transmission

1994 Dodge 2500 4x4 reg cab CTD/Auto with some go fast parts

Sold:
95 Chevy 6.5 Diesel 2500 4x4 Auto - 129k miles





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Old 03-14-2015, 01:04 PM   #9 (permalink)
Tommygunner
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I buy parts from drivetrain.com. quality parts, and ship fast. They have tech support too if you have questions during assembly.
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Old 03-29-2015, 09:23 PM   #10 (permalink)
Cumminsdriver
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Well I finally got my parts. Ordered them from midwesttrans.com. They seemed to be the cheapest I could find and shipped out quickly. Cost me $144 for a new chain, new fork pads, and new range fork. Bearings, gears, and shafts all still looked fine so I didn't bother with anything else. Took my time and got the T-Case all back together Friday night except for the tailhousing. I didn't order a new snap ring for the main shaft and it was loose when I put it back on so I decided to buy a new one. All I have to do it slide it on and put the 4 bolts back into the tail housing with some RTV on it and then stick it back in the truck. I took quite a few pictures and haven't uploaded them onto the computer yet.

For anyone curious, these things are actually very simple inside. If you are fairly mechanically inclined and have some basic tools, its not a bad job at all.

Im kind of missing driving the old 6.5. May try to finish the T-case and slap it in Tuesday or Wednesday, then possibly fix the cab mounts this coming weekend and hopefully get back to driving it.

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2001 Dodge 3500 Ext Cab Dually 4x4 CTD/Auto. Edge Juice CTS, Air Dog, 6" Stacks, 285 Nitto's - Self Built Transmission

1994 Dodge 2500 4x4 reg cab CTD/Auto with some go fast parts

Sold:
95 Chevy 6.5 Diesel 2500 4x4 Auto - 129k miles





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