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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 03-22-2015, 01:22 PM   #41 (permalink)
bk95td
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Finishing up IP swap

I got back at it yesterday and finished getting things put back together.
The one noteworthy thing was the tin heat shield that goes between the turbo/exhaust manifold and the valve cover-injectors-return lines. It is very hard to see the bracket and the tabs that go in the slots on the tin shield. The shield is a 2 layer piece. if the tabs aren't installed correctly, there could be a rattle that would drive you crazy trying to find. The rattle can occur at only certain RPM or load conditions. The tab should go in the lower slot and back behind in the upper slot. I had a extra bracket to show the pieces better. With the exhaust manifold and turbo on it is very hard to see and near impossible to get a picture of.
The rest of the assembly is pretty straight forward. I put RTV silicone sealer on the inside of the rubber hose that connects the upper intake and turbo.
Up next will be making new battery cables. This truck already had a custom 2-0 cable from the passenger side battery to the starter. I had that made a few years back and had it on my 91 K2500 6.2. At that time I had been having cranking speed problems and had replaced the starter and batteries. I had only the positive cables made. With dual post batteries, I tied the two together using the top posts and ran the starter cable from the side post. The difference in cranking speed was unbelievable. Obviously the OE cables were shot and marginal in size.
This truck will be getting a new 2-0 side post crossover cable, Both new 2-0 ground cables both with new 8 ga body grounds and most likely a new 8 ga. charging wire from the alternator to the battery.
I will be starting another thread on just the making of the cables so that it will be easier to find in a search. The thread will be posted in the 6.5 section but may get moved to the main electrical section.
I will be coming back to this thread for the install of the custom cables and the rest of what I do to get this truck on the road and other work and mods to it.

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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 03-25-2015, 10:03 PM   #42 (permalink)
bk95td
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The good news and the bad news

I got back to working on the trck after making the needed battery cables for it. Here is a link to the battery cable thread: https://www.dieselplace.com/forum/63-...-93-6-5-a.html
I didn't have a pair of batteries for this truck, so I "borrowed the set out of my 94 burb with the bad engine. They are Exide 900CCA dual post batteries.
I used stainless steel bolts to connect the new cables to the batteries.
I did make one mistake with the cables I put the wrong body ground wires on the ground cables, so I still don't have a body ground coming off the driver's side battery. Since I am waiting on the supplies for a new 6 gauge charging wire, I had to attach the OE charging wire to a top post.
I had to use some new clamps to hold the bigger cable running over the fan shroud.
This afternoon I thought I'd see if it would startwith the replacement IP. I went through 5 cranking and waiting cycles and it started. The cold advance was working for sure! It really had a very loud rattle with the hood open. After a couple minutes the advance kicked off and it quieted down some but not as much as I thought it should. It does have new injectors and a new timing chain , so it should quiet down some in a few miles. It ran nice and even and no smoke.Much better than it did with the old IP.
So much for the good, now for the bad. It pumped out 1/4 of a quart of ATF out of the torque converter cover drain hole. It also has a fuel leak that appears to be coming from the FFM. Probbly the o-rings for the water in fuel sensor and or fuel heater. I have new o-rings for both. Also the tach and fuel gauge don't work and I found where the rear brake line is rusted out.
The good news of this is that I do have a spare transmission that came out of the same truck as the IP. It's a Goodwrench reman. I just have to hope it isn't as trashed as the engine in that truck was[2 pistons melted to the compression rings]. The truck was a 93 K3500 SRW extended cab that I bought for parts a few years ago for $500. I'm thinking of putting all new electronics in the trans before putting it in the truck. For the $150 it is worth it for the peace of mind that it is all new. This is the kit I have put in 3 other transmissions: 4L80E Master Solenoid Kit 1991 to 2003 It is all OE or better parts. I've done the others with the transmission in the truck. This should be quick and easy with the transmission on a engine stand.

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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 03-25-2015, 10:12 PM   #43 (permalink)
dieselmike1
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Them are some nice looking, beefy cables.
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Old 03-28-2015, 01:22 AM   #44 (permalink)
Crazyxxxinsane
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Love the work man, turned out nice and clean, the way it should be. Well worth the time and effort put into it
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1995 Chevrolet K1500 4x4 ECSB - 230,xxx Miles - New PMD and Relocation kit - Custom 3" bent down pipe and cross over -Pillar Gauge Pod -Rancho Steering Stabilizer HX40W Turbo -New Harmonic Balancer - 8k HID headlights -"Buddy Chip" - OPS/LP Relay kit installed - New Heavy rear coil over shocks - new glow plugs -"F" Style intake - EGR Delete
1994 Chevrolet K1500 Reg Cab Long Box - Gifted to my father for a surprise
1998 GMC ECLB Dually. 197K Miles-PMD relocate-new IP last year-glow plugs-New Brakes all around-Running board lights-customized FFM relocate-rebuilt injectors-Diamond Eye Exhaust
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Old 03-28-2015, 11:14 AM   #45 (permalink)
kerrye
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Hint: I slip a piece of heater hose over the battery bolts to avoid inadvertent shorting out. I do this because I was once working on a car with a guy wearing an expandable metal watchband which hit both the positive post of the battery and a ground. He now has a permanent 'tattoo' of the watchband embedded in his wrist from the burn.
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Old 03-31-2015, 11:23 PM   #46 (permalink)
bk95td
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New tools to continue the project

I went shopping yesterday and came home with a new 2000lb transmission jack and a new 1000lb engine stand.
I have several other engine stands but they are occupied right now and I don't feel like going through the trouble of building my own. I bought this to put the transmission on that will be going in this truck. I'll be putting in the electrical kit, So I will need to roll it over.
The stand came un-assembeled. I added extra washers in a few places to help strengthen it. I also greased the wheels and swivels on the casters before they got bolted on. I have another stand that is a twin to this one, that came with one of my suburbans. It hadn't had this done when it was put together and the wheels were locked up and casters wouldn't hardly swivel. I paid $50 for this new stand. Pretty hard to buy the materials and spend the time making one for that price.

I looked at other transmission jacks and decided on this because it is rated for 2000 lbs and it will lift to almost 30". The others I looked at only lifted 1000 lbs and only to 23 inches. This jack weighs over 150 lbs. The jack cost $224. I have at least 3 other trannys to do with it right now, so It should get used enough to be worth having. It will also work for doing fuel tanks and a few other lifting tasks.
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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 04-01-2015, 12:03 AM   #47 (permalink)
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Nice new toys
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Old 07-31-2017, 11:18 PM   #48 (permalink)
bk95td
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Moving on to transmission replacement

It's been a while since I posted on the progress. I got too into the tranny replacement and didn't post the pics, so here are some. I didn't replace all the electronics as I thought I might. I did replace the OEM pan with a B&M cast aluminum one. The aluminum pans are not cheap . They do offer better sealing and extra capacity, beside looking very good I also bought a oem style composite re-usable gasket. I like that they have a solid piece around the bolts to prevent over-torque ans bending the pan. I doubt the aluminum pan would bend much because the bolting flange is over 3/8" thick. I cleaned the tranny up and painted it with Aluminum colored engine paint and then clear engine paint.
Other things of note were I replaced the input and output shaft seals on the transfer case. The input seal usually start to leak around 200,000 miles. The transmission fluid will leak in and over-fill the transfer case.. I also replaced the o-ring seal and gasket between the transmission and adapter and transfer case.
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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 07-31-2017, 11:35 PM   #49 (permalink)
bk95td
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Transmission in. Connecting driveline

While the driveshafts were out I thought I should clean them up and paint. A couple of the u-joints were shot, so they got replaced before painting.
There, caught up to what started this week.
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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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Old 08-01-2017, 12:28 AM   #50 (permalink)
bk95td
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Another set back

After getting the drive line hooked up, I took the truck for a test drive. Not only were the rear brakes not working because of the rusted line, but the rear brakes were dragging as were the fronts. To make matters worse, the check engine light was on and the torque converter wouldn't lock up.
Fortunately the check engine light and torque converter lock up was a easy fix. The was a single wire connector that didn't get plugged back together.
The brakes were going to need major work. I filled the brake fluid and pumped it up to find the leak in the rear line. The line going to the rear had been replaced once already but rusted out by the plastic clips that hold it to the frame. To my surprise both lines running across the rear axle also blew out. So it will also need new wheel cylinders because the bleeders will be rusted tight. To make matters worse, the brake adjusters had seized up I was able to get one drum off without a fight, but the other required big pry bars to break the hold down retainers then pry the shoes out of the drums.
The brake shoes were wore thin and pieces were missing. The drums were grooved up from the rivets.
Moving on to inspect the front brakes. The right front caliper was seized, pads wore bad and rotor was shot. the boot on the cv shaft also was torn The left front just had worn pads and shot rotor.
I went and checked my parts inventory and found a set of usable drums and a cv shaft. The rest of the parts used to revive the brake system will be new NAPA parts. I've used their brake parts for many years and only had trouble with one caliper.
My shopping list was: 2 reman coated calipers, rotor -pad kit [semi-metalic], new hoses, wheel cylinders, brake shoes[semi-metalic] Hardware-spring kit, rear hose and the spring clips that hold the hose to the frame mount. I have steel line and brake fluid. The NAPA total was $530.
Something to remember with this truck is that it hadn't been driven in 7 or 8 years, it has 200,000 miles on it, it has a 5th wheel ball hitch and may have had a snow plow on it. It's also a 24 year old truck.

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__________________
91 K2500LD reg cab 6.2 4L60 deceased at 310k
92 k2500hd 6.5 4L80E std cab died of frame cancer285 k
4- 93 k2500hd 6.5 2-4L80E 2-NV4500 2-ex-cab 2 std
94 K2500HD 6.5td 4L80E new reman engine
94 K2500HD 6.5td NV4500 Std cab LB
2-94 K1500 Ex cab 6.5TD 4L80E 1-LB parts truck 1-SB
94 k25000 Suburban 6.5td 4l80E
95 tahoe 2 dr 6.5 4L80E needs HG or engine
95 k2500LD 6.5 4L80E std cab bad trans
95 k2500hd 6.5 4L80E ex-cab
2-95 K2500 Suburban 6.5TD 4L80E both need engines
97 k2500hd 6.5 4L80E std cab
97 k3500 C&C 6.5 4L80E std cab needs engine
98 k2500 hd 6.5 4L80E std cab bad trans
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