Teardown and Rebuild

[Mopar1973Man]

I just exit a convo when someone says they "need 600 hp to tow their loads"  

I just think to myself, what are you driving a semi with a 5.9 in it???  laughable.

I tend to agree. It these very same people you'll find later on with more issues transmission & driveline wise. Constantly fight to keep things from breaking and failing on the highway.

Then look like this towing...

 

[TFaoro]

Went on a posting rampage there Mike haha!

You're right though. My dad's 96 12v isn't much over stock and it hasn't had a single thing break in 150k (that was caused from power.) He fixed the 5th gear with a full splined mainshaft and replaced a couple fuel lines. It didn't move for the first 90k unless it was hooked up to the 25ft gooseneck stock trailer.

Edited October 30, 2015 by TFaoro

[JOHNFAK]

Don't mention CFM... I think he has you beat. 

Well he used to  

Now I'm pushing 80+ on a 63/71/14 over 475/96/1.25 .......

I need to find a way to get W&F down here to Florida to rebuild my engine ..... see if I can get over 800HP. Common Bill ..... I'll pay for your trip Heck - even throw in beer

 

[JOHNFAK]

Just read the entire thread on a road trip. Some questions.

Is your knocking gone now with the fix of fuel leaks.

What rebuild book did you use or follow for clearance spec and check.

Did you weight balance the pistons and rods.

Did you have crank balanced when polished. 

What head studs did you use... 425/625/H11 

Have some questions on machining costs ... might pm you unless you want to share here. 

Any tips on reinstall .. always figured that would somewhat be hard going back in with harness and wiring .... you probably still had yours removed.

Biggest lessons learned ? . Do differently or wasn't aware when you started. 

 

Great stuff.....

 

Edited October 31, 2015 by JOHNFAK

[TFaoro]

Just read the entire thread on a road trip. Some questions.

Is your knocking gone now with the fix of fuel leaks.

Most of it... Nick can attest to that yesterday. I've still got fuel leaking from the #3 line where it connects to the crossover tube, so it's got just a bit of a tick to it. 

What rebuild book did you use or follow for clearance spec and check.

A cummins ISB book.

Did you weight balance the pistons and rods.

Did you have crank balanced when polished. 

No and no. I can't even get over 3500rpm so I wasn't too worried about it.

What head studs did you use... 425/625/H11 

425's

Have some questions on machining costs ... might pm you unless you want to share here. 

Head was 1300 bucks, rebuild kit was just over a grand, and having the block was around 700

Any tips on reinstall .. always figured that would somewhat be hard going back in with harness and wiring .... you probably still had yours removed.

I left the harness off. I also changed the mounting locations of it. I'd leave it off to go back in. The install is pretty easy with two guys. Just make sure you lift the engine far enough forward that it leans backwards.

Biggest lessons learned ? . Do differently or wasn't aware when you started. 

 

Great stuff.....

 

Thank you! Um.... make sure you have the money going in. I think when it was all done I'm over 6k into it.

 

Got the gauge in last night. I'm a little pissed off though. Spent 80 bucks on a 100psi gauge and it's bad. It sticks at 40 unless you hold it at 55psi for a few seconds. Then it'll slam over to 60 then back to 55. O well... I'll get it straightened out this week.

I currently have the boost elbow completely closed off and I'm seeing 20 from the primary and 55 over all. This tells me the drive pressure is pushing the gate open.

Also, I was playing with the tst and I'm seeing 55psi whether the tst is on 9, 7, or even level 3. The power feels the same and the boost is exactly the same. Is this because of the small injectors??

[AH64ID]

. I think when it was all done I'm over 6k into it.

What all does that include? Cam? Twin kit? etc

[TFaoro]

Everything before the twins engine wise, a cheap trans rebuild kit, fluids, paint, etc

And another gauge is in

[JOHNFAK]

6 hours ago, TFaoro said:

I currently have the boost elbow completely closed off and I'm seeing 20 from the primary and 55 over all. This tells me the drive pressure is pushing the gate open.

Also, I was playing with the tst and I'm seeing 55psi whether the tst is on 9, 7, or even level 3. The power feels the same and the boost is exactly the same. Is this because of the small injectors??

Supposedly the gate will open anyway from DP like you said. So going to hard to know when with the elbow closed. I cant see what fuel your running but if your limiting out like that then yeah thats the most likely cause - lack of fuel. Suprised your not driving that primary harder though as its a smaller turbine from memory on what you posted. Id get the secondary to start opening earlier and see if you can push the primary to 25-28 ......

2 hours ago, TFaoro said:

Everything before the twins engine wise, a cheap trans rebuild kit, fluids, paint, et

 

So $4k for engine ballpark ?
Gotta get my compression test done here soon ....... and decisions decisions.
Did the machine shop use a torque plate when bored the block ? 

[TFaoro]

No.... machining and rebuild kit 3k Other hard parts around 2400 (cam, tappets, pushrods, springs, oil cooler, oil pump, billet piston cooling jest, and probably more). It should help already having the top end parts but to be safe I'd still say a safe number is 6k.

I can open the elbow and see what it does, but I'm betting the gate is wide open from drive pressure already.

For fueling I've got a smarty, TST comp, DAP 125's and a SO VP. Higher tst numbers just give me higher egts. The boost is staying the same. 

[TFaoro]

Opened the boost elbow 3/4 of a turn this morning. Primary was pushing 30psi but not sure about overall thanks to the POS gauge in there. Also gave her a wash last night. 

[Me78569]

Glad to see you made it to denver :shifty:

[TFaoro]

9 minutes ago, me78569 said:

Glad to see you made it to denver :shifty:

Got the tires balanced yesterday!! Hopefully that'll stop the death wobble at 90  Just have to wait and see I guess!

[Me78569]

hope so.

[JOHNFAK]

3 hours ago, TFaoro said:

Opened the boost elbow 3/4 of a turn this morning. Primary was pushing 30psi but not sure about overall thanks to the POS gauge in there. Also gave her a wash last night. 

Bet overall was slightly higher but you should have noticed more pull ...

Then yeah think it's fuel. That setup your running is good for around 500hp ... so 55-60 on twins sounds about right.

[TFaoro]

3 minutes ago, JOHNFAK said:

Bet overall was slightly higher but you should have noticed more pull ...

Then yeah think it's fuel. That setup your running is good for around 500hp ... so 55-60 on twins sounds about right.

It made 500 before twins... I sure hope it's burning more of that fuel and making more power than it was. It was pouring black smoke even when spooled on the single. 

[JOHNFAK]

You should be able to feel/know. More a generalisation based on fuel/air.

I ran the same box and injectors on a he351/s472 and it was just short of 500hp. Each truck is different.  

[TFaoro]

1 hour ago, JOHNFAK said:

You should be able to feel/know. More a generalisation based on fuel/air.

I ran the same box and injectors on a he351/s472 and it was just short of 500hp. Each truck is different.  

No doubt about that.

Anyone want to send me a set of injectors?? 

[Texas CTD]

I think it would be interesting to see a current dyno number. You made 500 twice, and the only major difference as far as power goes, would be the compounds. You did upgrade the TST though, so that might change it a little. 

 

Just to see how much more power it makes with more air, and then dyno again with new injectors. 

[TFaoro]

13 minutes ago, Texas CTD said:

I think it would be interesting to see a current dyno number. You made 500 twice, and the only major difference as far as power goes, would be the compounds. You did upgrade the TST though, so that might change it a little. 

 

Just to see how much more power it makes with more air, and then dyno again with new injectors. 

Can't forget about the cam too.... 

The tst fuel harder sooner, but level 3 and level 9 on the tst feel no different, so I wouldn't say that changed too much.

My school's race club is supposed to be doing a dyno day in the next couple weeks! They are making me go last though... last time they think I was the one who broke the dyno  

[Texas CTD]

Awesome! Hopefully you get to jump on. Very curious to see what it makes with the same sticks.