RamCharger.net

Tech => Projects => Topic started by: rjtx667 on January 11, 2015, 08:39:38 pm

Title: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 11, 2015, 08:39:38 pm
so  I made the fatal mistake at work again this week... I started browsing craigslist.

Found a 2005 cummins 2wd truck. the ad said:

I have a white 2005 5.9l Dodge Cummins 2500 truck, 156,000 miles. It is broke down, I have heard everything from a dropped rod to a bad oil pump to a backed out flywheel bolt. the engine starts and runs, but has a knocking noise coming from the bottom of the engine where the engine and torque converter meet. I have had the torque converter checked, flywheel checked, engine checked, and the best anyone can say to me is to get a new engine which i am not financially willing to do. The truck itself is in good condition, infinity sound system, spray in bed liner, air shocks under the bed for heavy towing, leather electric heated seats, heated mirrors, 6 disc cd changer, hide away goose neck hitch. I am tired of dealing with it. Once I get the title for it I will sign it and mail it to you.

 I don't know whats wrong with it, you will have to pick it up with a flatbed trailer. Cash only, once up and running the blue book value is close to $20k. If you have good knowledge of these trucks then this is the truck for you. Come get it!!!


-

So I looked at it Thursday and decided to give it a go. Finally got it home tonight. It knocked real bad and would not even get itself up on the trailer (had to winch it), got it to my house and drove it into the driveway and the knock went away. That seems to be suggesting a fuel related issue of some kind.

gonna see if I just got a heck of a deal, or if I got screwed. Hopefully its a deal and I have a new tow rig.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 11, 2015, 08:53:43 pm
Hell YEAH  :thumbsup:

Hope you get it fixed up! One hell of a tow rig
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 11, 2015, 08:55:01 pm
I sure hope so, the price was right for me to roll the dice.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on January 11, 2015, 09:02:15 pm
Pretty soon you are gonna need to move into a warehouse or ranch. 
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 11, 2015, 09:09:12 pm
Pretty soon you are gonna need to move into a warehouse or ranch.

Pretty Soon his place will look like my ranch and Noah's shop  :laughing4:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 11, 2015, 09:25:28 pm
pretty sure my neighbors would complain I am running a used car lot, except none of them ever seem to stay gone lol  :laughing7:

I do want to try and save a little to put down on a few acres outside of town, but that will take a while.  If other members lived closer to DFW I would not have to worry as much about that  :evil6:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 11, 2015, 09:30:40 pm
pretty sure my neighbors would complain I am running a used car lot, except none of them ever seem to stay gone lol  :laughing7:

I do want to try and save a little to put down on a few acres outside of town, but that will take a while.  If other members lived closer to DFW I would not have to worry as much about that  :evil6:

Maybe you should move further south  :tongue3:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 12, 2015, 05:48:44 am
the court of tarrant county says I cant  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on January 12, 2015, 10:36:52 am
Get a big enough ranch and we will all move in with you.   :13:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 12, 2015, 12:25:09 pm
If its that big we would never leave as it would be a 24x7 Offroad outing lol  :headbang:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on January 12, 2015, 04:40:23 pm
Sounds like a win win. :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 12, 2015, 08:16:22 pm
I know Noah Has been working on a few of these newer cummins trucks with Bad Fly Wheels. Maybe Give him a call, he may be able to lead you in the right direction.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 12, 2015, 09:11:44 pm
I believe his exact words were "Scary" lol

Ernest has been giving some advice, so I am starting with basics, check fuel and send off a oil sample for testing.

I am going to remove the inspection plate and check the flex plate as well.

after that it's down to leak down test/ compression test, then remove injectors for testing and injector pump for testing.

it's parked outside right now so just have to take it slow.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 12, 2015, 10:22:56 pm
I believe his exact words were "Scary" lol

Ernest has been giving some advice, so I am starting with basics, check fuel and send off a oil sample for testing.

I am going to remove the inspection plate and check the flex plate as well.

after that it's down to leak down test/ compression test, then remove injectors for testing and injector pump for testing.

it's parked outside right now so just have to take it slow.

Well I hope it works out that would be one hell of a truck!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 15, 2015, 04:01:38 pm
Any word on whats wrong with the truck?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 15, 2015, 04:50:38 pm
going to do a blow by test tonight and check the fuel filter. everyone things injectors but not sure yet. I ordered the tools to pull injectors and they arrive Friday, so hopefully I can pull them this weekend. then need to figure out how to do w compression test on it and go from there.

if the po ran it too long with a bad injector it will need a rebuild which will sux, the blow by test should tell me if its bad or not
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 15, 2015, 05:46:25 pm
Hopefully it checks out, Would be a nice rig to have  :steeringwheel:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 15, 2015, 07:24:47 pm
Well progress. I have some video's I need to try and get uploaded so you can hear the knock... its kind of scary sounding on the video  :violent1:

But when I fired it up tonight it had no knock until I pulled it in the garage, but man was it spraying for mosquito's  :laughing7:


So I took a few pics so you can see the nice dirty engine. I also did the blow by test, which is really easy. The theory is if you have a bad ring or something its going to put a lot of pressure into the engine block, so  if you take the oil fill cap and have it sitting just on top of where it goes... if it bounces around like crazy there is lots of pressure, if not then your good. I saw a video on you tube of a bad one, mine did not do that  :13:

People with the nice fancy scanners (my mt2500 is too old) can kill injectors 1 at a time to test for bad ones. Well I don't have that, but what I do have is a brain. so my plan.... there are 3 connectors for the injectors, 2 per... knock is from the back. I unplugged injectors 5 and 6. Started it up (it was harder to start), was not happy at all.... and... DID NOT SMOKE!!!!!  :13:

So I believe the best  thing to do next, since I have just proved there is at least 1 bad injector, is to order all new injectors and see what it does after that.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on January 15, 2015, 07:50:17 pm
Very Interesting  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on January 16, 2015, 11:47:21 am
good progress... good choice on replacing all injectors... they will be needed regardless of the condition of the motor... you should sample the oil that is in it currently. It will have lots of diesel in it obviously, but it will be important to compare it with another oil sample after the injectors are changed (change fuel filter, engine oil and filter before running it with the new injectors) to better determine if any bearings/pistons/etc are damaged.  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 22, 2015, 03:01:45 pm
Ordered 6 Brand new Bosch injectors + install seal kit + feeder tubes. Will be in sometime next week.

I also ordered a after market 2 stage filter kit. It does fuel filter + water filter. The fuel filter goes to 2 microns vs the stock 7 micron. its also suppose to be more effective 98% vs 60%.

I also figure I need to dump a ton of fuel out, its got about 3/4 of a tank and I don't trust it. So now I have to figure out how to dump it and dispose of it, drop the tank and clean it then fill it back up.

Should be fun.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 22, 2015, 10:00:28 pm
well looks like no more fun on this  :violent1:


I need to look and test a bit more, but to me that looks like a start of a hole in cylinder #6's piston?

Its not a hole yet, and its not got blow by... so not sure what that means. But I know it would mean a new piston if you want to be on the safe side.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on January 23, 2015, 07:33:48 am
well looks like no more fun on this  :violent1:


I need to look and test a bit more, but to me that looks like a start of a hole in cylinder #6's piston?

Its not a hole yet, and its not got blow by... so not sure what that means. But I know it would mean a new piston if you want to be on the safe side.

the large circle in the middle is normal shape of the piston crown.... not sure about the small shiny spots.... maybe just some residual liquid reflecting...
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 23, 2015, 07:40:35 am
I had seen some pistons like that online and I wondered... that would be fantastic news!!!! :13:

I have to get where I can rotate the engine around and get better shots of all the pistons.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 25, 2015, 08:22:40 am
turned the engine around to look at all the pistons, they all have that spot... just in varying scales of visibility due to carbon.

The cylinders where the injector was failing seems to be cleaner as it was washed a bit... or maybe those are the dirtier ones? Not sure.

Injectors are here tuesday.


Thinking a leak down/ compression test would be nice, but I don't have the adapter to do it.  :icon_scratch:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 29, 2015, 10:40:11 pm
I broke down and bought the adapter to do the leak down test.

Cyl 1 - 20% - not sure I had the valves closed all the way
Cyl 2 - 5%
cyl 3 -11%
cyl 4 - 9%
cyl 5 - 13%
cyl 6 - first time was 53%, I put a little ATF down it and it went down to 32%

all in all not too bad, and considering your suppose to do this with the engine warm and it was really cold. I figure cal 6 was higher because it had been washed with the bad injector.

Got it all put back together and there was a strange clicking sound, and I had 3 check engine lights. I thought it might be the injector harness's. Bought 3 new harness's and the sound was there but the CEL was different.

I also bought a new after market fuel filter, a big bad one lol. It came in and I installed it. The factory filter was way nasty dirty so that was replaced as well.

I went ahead and started it up, took a few times to prime and clear the air. I had the door open, as soon as it started the horn was going and lights flashing. Really freaked me out, I closed the door and it went away. Finally figured out it thought it was in gear and was doing that was a warning.

It started good, seem to idle good and the smoke was gone. There was a little, but that ATF had to get cleared up somehow  :evil6:

It still has a knock, but I found I can make it come and go... it comes with higher idle or trying to put any load on the truck while driving. IE it can idle and accelerate fine but you give it gas over 1k RPM and it makes the sound. You stop and put it in reverse and it seems to go away. Sounds like a flex plate to me. I am going to try and check the inspection plate tomorrow and see what I can see.

But the engine runs again and sounds good at idle when the knock is gone. I am excited  :dance:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on January 30, 2015, 09:14:51 am
All right, sounds like progress.   :13:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on January 30, 2015, 09:53:26 am
not driving progress, but its in the right direction.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 05, 2015, 12:44:30 pm
Anymore progress on this beast?

I'm curious how it will turn out because that thing will make one hell of a tow rig!  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 05, 2015, 12:47:10 pm
it runs lol

I plan to get into the inspection plate and trying to look to see if I can find anything and go from there

I will update tonight.

if I do need parts there is a lead time for the new converter
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 05, 2015, 01:01:24 pm
Probably would be a good idea to fill the converter and replace fluid and filter while your working on the transmission.

Maybe i missed it but what is the total mileage on the truck?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 05, 2015, 01:22:30 pm
156k

and yes transmission is getting new filter, probably a deep pan and new fluid.

if I have to drop the transmission for the flex plate then I will do the new converter and valve body as well.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 07, 2015, 11:45:56 pm
I believe its time for a Update :protest:


 ?  :steeringwheel: ?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 08, 2015, 07:18:28 am
about the same spot as last time, I got the inspection plate off and it shows you jack. removed starter snd nada. finally found s little plate on passenger side that covered 2 holes, one apparently for a tool to turn the crank the other a hole to remove the torque converter bolts.

well got all set up to try and start removing bolts and then I started feeling bad and had to call it a night. Friday after work I had to jump on a plane to Amarillo to help my folks move.

so maybe sometimes this week I can try to finish removing the bolts to see what I can see.

I did not see metal chunks or the like when I removed the inspection plate.  :icon_scratch: :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 08, 2015, 11:56:22 am
Well at least you are making progress.

A side from the vehicles that you have listed in your signature, How many do you have now with this one?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 09, 2015, 01:28:54 pm
Lets see

1991 Ramcharger - has a 92 Magnum 318 in it
1993 Ramcharger - trail rig
2000 Ramcharger
2000 dakota (ready to sell, tired of dealing with it)
2003 durango (now daily driver)
2005 Cummins

I did not include the 1985 parts truck at Noah's

I also have

1989 Bayliner boat
1995 Jetski

I am way past out of room for my toys  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 10, 2015, 12:08:07 pm
Lets see

1991 Ramcharger - has a 92 Magnum 318 in it
1993 Ramcharger - trail rig
2000 Ramcharger
2000 dakota (ready to sell, tired of dealing with it)
2003 durango (now daily driver)
2005 Cummins

I did not include the 1985 parts truck at Noah's

I also have

1989 Bayliner boat
1995 Jetski

I am way past out of room for my toys  :laughing7:

Damn that's a collection!
Your as bad as Me and Noah  :laughing4:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 10, 2015, 01:40:28 pm
At least you guys are in the country. Ryan has a beautiful house in the suburbs.  His trail rig is a jungle gym in the backyard. Lol.  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 10, 2015, 01:54:25 pm
At least you guys are in the country. Ryan has a beautiful house in the suburbs.  His trail rig is a jungle gym in the backyard. Lol.  :laughing7:

Dodge's look better then lawn gnomes, But Im sure the HOA doesn;t agree with that...
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 10, 2015, 02:05:28 pm
No trailers in the driveway, but can be in the back yard as long as its not overly obvious.... so they don't really care.

now leave a car hauler in the driveway for a week and they are flipping out  :violent1:

maybe in a few more years I can find a place more suited for my hobbies  :laughing7:

My old brother in law tells me to sell the house and just buy a work shop that has living quarters on the end of it  :evil6:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 10, 2015, 02:42:56 pm
No trailers in the driveway, but can be in the back yard as long as its not overly obvious.... so they don't really care.

now leave a car hauler in the driveway for a week and they are flipping out  :violent1:

maybe in a few more years I can find a place more suited for my hobbies  :laughing7:

My old brother in law tells me to sell the house and just buy a work shop that has living quarters on the end of it  :evil6:

Thats my goal is to buy some property and build a  shop with a apartment.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 10, 2015, 07:29:46 pm
X3 on that.   :great:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 11, 2015, 02:08:00 pm
Fingers crossed it goes well tonight, going to try and finish getting the torque converter loose.

Check out the flex plate and possibly start it with the converter loose.

If I can get all that done I will have all my answers I need.... I hope lol :tard:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 11, 2015, 03:17:40 pm
Fingers crossed it goes well tonight, going to try and finish getting the torque converter loose.

Check out the flex plate and possibly start it with the converter loose.

If I can get all that done I will have all my answers I need.... I hope lol :tard:

Are you just unbolting the Torque Converter? Or the whole transmission?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 11, 2015, 04:02:48 pm
just the converter for now.

There is enough clearance to start it with it pushed back.. just barely.

The magnum's have the starter teeth on the convertor so that does not work so well.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 11, 2015, 04:18:49 pm
just the converter for now.

There is enough clearance to start it with it pushed back.. just barely.

The magnum's have the starter teeth on the convertor so that does not work so well.

I'm curious about how this will go. I've never seen it done this way.

Good Luck  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 12, 2015, 09:41:38 am
well it did not go as I wished....

Got the converter loose and pushed back, still could not see much. the flex plate seemed solid and not moving.

I connected the starter back up and started it. The converter was free wheeling from the wind of the flex plate.

The sound was still there.

Could be the flex plate still, or could be something in the engine.Its just strange to me it does not make a sound until 1200 RPM?

I am going to get a oil sample off and see what they find with that. I also want to check and see if the crank has any play in it from the flex pate... someone suggested that online as well.

I am really starting to worry I might have to pull the engine. I don't want to do that... rebuild kit is 1500 + machine shop cost.

I think my engine hoist could pull it out (2ton), but I would need a HD engine stand and who knows what else.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 12, 2015, 12:15:50 pm
well it did not go as I wished....

Got the converter loose and pushed back, still could not see much. the flex plate seemed solid and not moving.

I connected the starter back up and started it. The converter was free wheeling from the wind of the flex plate.

The sound was still there.

Could be the flex plate still, or could be something in the engine.Its just strange to me it does not make a sound until 1200 RPM?

I am going to get a oil sample off and see what they find with that. I also want to check and see if the crank has any play in it from the flex pate... someone suggested that online as well.

I am really starting to worry I might have to pull the engine. I don't want to do that... rebuild kit is 1500 + machine shop cost.

I think my engine hoist could pull it out (2ton), but I would need a HD engine stand and who knows what else.

Indeed it is no easy task to swap a cummins out. I would lean towards a wrist pin or rod bearing failure judging by the conditions you describe. I would recommend a pre-built long block if it comes to that... the time and hassle of rebuilding an engine from scratch can be a pretty long process. A long block would allow you to pull it and swap over all the new crap and old crap that is necessary and then drop it back in much more efficiently than a total rebuild... but before all that you may need to decide if you will even be able to pull it out. I would recommend an a-frame with a hoist for that. I am thinking of building one for my shop to deal with the heavy/big shit that just doesn't seem to be safe with a conventional engine hoist... that and my tractor will only lift 900-1000 pounds which just isn't enough for a cummins  :violent1:

There is another option..... pull the head and the oil pan and if it is a wristpin making noise simply swap in a new piston and rod assembly for the one cylinder...it can be done..... if it is a rod bearing it may be salvageable without machining...maybe... you would have to inspect the rod journal for wear/measure/polish... same applies replace piston and rod assembly and install new bearing


I would put money on a wristpin/piston to be the source of your noise....It can be repaired without pulling the motor....just some gambling involved  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 12, 2015, 01:01:38 pm
Yeah the next step is sending off the oil sample. That should give me a good indication of what to do next.

From looking around, a long block is about 3700 where the rebuild kit is 1500 + whatever a machine shop would charge. My guess is $800 or so depending on what needs to be done.

Just have to see, I might pull the head and pan soon to look it over. I know cylinder 6 is weaker than the rest, so thats the most likely problem.

I had hoped for an easy fix, and its not been that yet. I still think it can end up an ok deal... just not the great deal I wanted.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 12, 2015, 01:30:31 pm
Yeah the next step is sending off the oil sample. That should give me a good indication of what to do next.

From looking around, a long block is about 3700 where the rebuild kit is 1500 + whatever a machine shop would charge. My guess is $800 or so depending on what needs to be done.

Just have to see, I might pull the head and pan soon to look it over. I know cylinder 6 is weaker than the rest, so thats the most likely problem.

I had hoped for an easy fix, and its not been that yet. I still think it can end up an ok deal... just not the great deal I wanted.

Personally I would pull the Oil Pan First to check all the piston rods, bearings, and Crank. Plus you can learn a lot about a engine by looking at the bottom of a oil pan.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 12, 2015, 03:52:31 pm
Personally I would pull the Oil Pan First to check all the piston rods, bearings, and Crank. Plus you can learn a lot about a engine by looking at the bottom of a oil pan.

yep.... you might find part of a piston skirt... or just a bunch of metalic aluminum sludge... not much to see with the head off.... you wont save that much (if any) over a long block by the time you are done trust me... best to get it pulled and undressed and haul it to wherever as a core. you will be happy when it saves you the hassle of having it torn down waiting on an engine for a month (or more).
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 13, 2015, 08:19:58 am
Well tonight I will get the oil sample ready.

It will take some work to pull the pan, you have to loosen the engine mounts and lift the engine 2-3" out of the truck. Or so they say.

Should be interesting next week.

Noah, do you have a recommendation as to where to get a long block if I do have to go that route? There are some places locally that would save the shipping cost, but I don't know their rep.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 13, 2015, 10:44:39 am
Well tonight I will get the oil sample ready.

It will take some work to pull the pan, you have to loosen the engine mounts and lift the engine 2-3" out of the truck. Or so they say.

Should be interesting next week.

Noah, do you have a recommendation as to where to get a long block if I do have to go that route? There are some places locally that would save the shipping cost, but I don't know their rep.

http://www.ebay.com/itm/2004-2007-5-9L-Cummins-Diesel-Engine-/221477201276?fits=Make%3ADodge

looks good to me... in dallas.... might call them direct and see if it is cheaper without shipping since you are so close
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 15, 2015, 02:39:09 pm
Any Progress?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 15, 2015, 09:52:54 pm
have the kids this weekend, and had to help my folks move some stuff.

I did get some time today, bought a 24 quart oil drain pan to be able to drain it and get the oil sample.

So I got the torque converter bolted back up and started it up. Let it idle a while to get up to temp and then drained the oil.

While running I had my neighbor rev it to 1200 or so, It seemed I could see the flex plate moving bit, like its warped but not broke?

I could not get the crank to move any, but could see the flex plate flex  a little.

So below are the pics of the oil.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 15, 2015, 09:54:04 pm
So the oil sample goes off tomorrow, but yeah I see metal flakes... question is metal from what?

At this point its starting to look expensive though  :violent1:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 16, 2015, 03:03:10 pm
What is that in the center of the pan in the last picture?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 03:05:20 pm
foil cover from changing the oil in the 03 durango before I tackled this one.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 16, 2015, 03:16:20 pm
From what I see in the picture I don't see any thing "Major", But pulling the pan will really give you a better idea on whats going on if its a internal engine problem.

If there a way to pull the Torque Converter and Flex plate, then start the motor it would eliminate those as potential problems, but you need something for the starter to engage on. I am un familiar what the new torque converters and flex plates look like. Im use to looking at TF 727 from the 70's and 80's.

I wish you had a Fly Wheel you could bolt up there so you could take off the Torque Converter and Flex Plate  and start the truck.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 03:33:19 pm
yeah plan to try and drop the pan this weekend. shall see how big of a pita that is. Sounds like its  huge, but shall see.

To drop the converter you have to drop the tranny. I might have to do that yet, as I am 99% sure there is an issue with the flex plate, but have to figure out the engine first.

The starter teeth are on the flex plate, so have to have it on to start it up.

I don't think most suggest it, but the manual says you can replace rods/ pistions/ bearing while the block is in the truck. Just have to pull her open and see how bad it looks.

what is strange to me, not that I know much, is how it can be an engine/ bearing/ whatever issue, yet it idles fine and sounds like nothing is wrong until you rev it up.  :icon_scratch:  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 16, 2015, 03:49:39 pm
yeah plan to try and drop the pan this weekend. shall see how big of a pita that is. Sounds like its  huge, but shall see.

To drop the converter you have to drop the tranny. I might have to do that yet, as I am 99% sure there is an issue with the flex plate, but have to figure out the engine first.

The starter teeth are on the flex plate, so have to have it on to start it up.

I don't think most suggest it, but the manual says you can replace rods/ pistions/ bearing while the block is in the truck. Just have to pull her open and see how bad it looks.

what is strange to me, not that I know much, is how it can be an engine/ bearing/ whatever issue, yet it idles fine and sounds like nothing is wrong until you rev it up.  :icon_scratch:  :dontknow:

Engine Harmonics and Vibration can be odd sometimes. At certain RPM a vibration can seem almost gone, but when RPMs are applied the rotational force and harmonics of the motor will amplify a vibrations that seemed like nothing at low RPMs.

The Cummins motor is a Shaker in stock form, So sometimes it difficult to determine a vibration at low RPMs because the motor shakes like hell stock.

Ask Noah why you shouldn't put a 360 Harmonic Balancer on a 318. Seemed fine at a idle  ::)
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 16, 2015, 05:02:59 pm
yeah plan to try and drop the pan this weekend. shall see how big of a pita that is. Sounds like its  huge, but shall see.

To drop the converter you have to drop the tranny. I might have to do that yet, as I am 99% sure there is an issue with the flex plate, but have to figure out the engine first.

The starter teeth are on the flex plate, so have to have it on to start it up.

I don't think most suggest it, but the manual says you can replace rods/ pistions/ bearing while the block is in the truck. Just have to pull her open and see how bad it looks.

what is strange to me, not that I know much, is how it can be an engine/ bearing/ whatever issue, yet it idles fine and sounds like nothing is wrong until you rev it up.  :icon_scratch:  :dontknow:

Dont waste your time ... pull the motor it is trashed
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 05:12:35 pm
Ask Noah why you shouldn't put a 360 Harmonic Balancer on a 318. Seemed fine at a idle  ::)

man that had to be fun, those harmonic balancers are engine specific... then again I have a 318 balancer on my mx RamCharger... can you figure out why? lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 05:14:48 pm
Dont waste your time ... pull the motor it is trashed

Noah, spoken like a true professional mechanic... I hope you are more gentle with paying customers
 :evil6:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 16, 2015, 05:15:55 pm
Noah, spoken like a true professional mechanic... I hope you are more gentle with paying customers
 :evil6:

nope...lol... the truth hurts....and I hate wasting time  :headbang:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 05:23:28 pm
it hurts a whole lot right now, to the point I almost don't want to go in my garage for a while :crybaby2:

I found a used cummins that seems too cheap, it's tempting but I know my score and luck with used engines  :violent1:

if it is a new engine then it sits a while as I don't have another 6k to drop into it.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 16, 2015, 06:20:17 pm

if it is a new engine then it sits a while as I don't have another 6k to drop into it.

Oh oh, open another credit card account.  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 16, 2015, 06:46:02 pm
Dont waste your time ... pull the motor it is trashed

I guess I am more of a optimist then Noah, He is much more of realist , Sadly more times then not he is correct.

I guess you could change the oil and run it till explodes  :headbang:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on February 16, 2015, 06:58:33 pm
Noah, spoken like a true professional mechanic... I hope you are more gentle with paying customers
 :evil6:

He's not....... It's like ripping off a band aid, Just rip it off quick and the pain will go away eventually.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 16, 2015, 08:58:54 pm
I guess I am more of a optimist then Noah, He is much more of realist , Sadly more times then not he is correct.

I guess you could change the oil and run it till explodes  :headbang:

I would run till it explodes, but I fear that might be at any time the way it sounds lol. Now if its a rod bearing, I don't mind changing that out and then running it till it explodes. Let me get some use out of the $$ sunk into it thus far.  :13:

As for ripping the band aid off... I never cared for band aids for that reason... nor do I really care for the pain even if it eventually goes away. I prefer to usually avoid the pain all together.... or think of something else until the pain goes away.

So yeah maybe I will focus on the heads on the 93. Thats a much less painful job  :tard:

For Noah's defense, he was not all that much for getting the truck in the first place... and he has not even done the I told you so yet... He's just done the spend the $$ lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 21, 2015, 12:27:57 am
well I am still a little confused, apparently I put my hand somewhere I did not realize or something.  :icon_scratch: :dontknow:

Oil report came back, and it seems to be the best $25 I have spent in a long time.

report is blow, and here is how you read it:

http://www.blackstone-labs.com/report-explanation.php

but the big thing is this:

RYAN: Thanks for the note about the knock. All the wear metals in this sample look normal, so we don't
see any obvious reason for it here
. That's good, because if the knock was a sign of poor piston or bearing
wear, it would probably show up as high metals, so at least we can be pretty confident you don't have a
major mechanical issue developing. Of course, the downside is, we can't really help you diagnose where
the knock is coming from. No contaminants or other issues were found. Averages are based on ~6,800
miles of oil use. Check back next oil to build trends.


so that means the knock has a good chance of being the flex plate. Either that or its not been ran enough to cause major damage to the bearing that is bad... but that seems hard to believe?

I am going to order the flex plate and other parts for the transmission and try to find a time to pull the tranny down.

As I said before, I could see when the truck was idling or rev'd to 1k rpm that the flex plate was not true and straight.

maybe it is cracked and it just takes 1k rpm to get enough of a load on it to cause it to hit whatever its hitting?  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 21, 2015, 06:58:01 am
I hope your right about the flex plate. That would be awesome. 
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 21, 2015, 08:03:29 am
there is hope  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 25, 2015, 09:23:53 am
Ordered the flex plate yesterday and went by harbor freight with my coupon and picked up a transmission jack.

Get it a little warm next week and let the fun begin.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 25, 2015, 10:59:58 am
Get it a little warm next week and let the fun begin.

No kidding, it was cold yesterday at 35*. I was fairly warm for awhile but my hands were freezing. :disgust:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 26, 2015, 09:31:21 pm
Well I got ahold of Martin at M Saine Performance today, I told him about the oil test and that I wanted the new converter and valve body.

He mentioned a slight issue, apparently its hard to come by 48RE valve bodies to tweak, and get all the parts you need. He said best thing was for me to pull it out and send mine in for  a modification.

A slightly bigger issue, after next Friday he is gone for a month  :confused2:  :violent1:

He said if I could get it to him ASAP he could probably get it all done and shipped back out before he leaves.

Well right now I am fighting the beginnings of a sinus infection and its about 35* outside... maybe warmer in my garage.

I am a determined fellow... I got it out planning to ship it out tomorrow AM for Sat delivery. I poked around at fedex, they are open till 8, its 7:45. I haul ass there. Walk in at 7:59 "I need to ship this out tonight" response "sorry can't its 8"
me: " no its 7:59"

needless to say after we finished arguing it was past 8  :angry4:

they did tell me another location (actually closer to my house) would ship till 8:30. I fly over there like there is no tomorrow (not bad for a 12 year old 200k mile durango) and have 10 minutes to spare.

It was not cheap, but the valve body will be there by 3pm tomorrow. So hopefully here in about a week or a little more I have a good box from Cali.  :13:

The flex plate comes in tomorrow, and I had a 20% coupon at harbor freight I used on a transmission jack.

I would not have had to do that if Noah would move closer to me   :laughing7:

I think I am about done for now, just wait till the parts get here then try and take it apart and put it back together in a weekend.

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: taz_man440 on February 27, 2015, 03:18:42 am
Wow..  What an ordeal...  At work we have twin 06 2500's.  Both have been severely abused and I often thought if they got ready to auction them I might throw an offer... But I really don't see that happening...
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 27, 2015, 08:03:24 am
Well I got ahold of Martin at M Saine Performance today, I told him about the oil test and that I wanted the new converter and valve body.

He mentioned a slight issue, apparently its hard to come by 48RE valve bodies to tweak, and get all the parts you need. He said best thing was for me to pull it out and send mine in for  a modification.

A slightly bigger issue, after next Friday he is gone for a month  :confused2:  :violent1:

He said if I could get it to him ASAP he could probably get it all done and shipped back out before he leaves.

Well right now I am fighting the beginnings of a sinus infection and its about 35* outside... maybe warmer in my garage.

I am a determined fellow... I got it out planning to ship it out tomorrow AM for Sat delivery. I poked around at fedex, they are open till 8, its 7:45. I haul ass there. Walk in at 7:59 "I need to ship this out tonight" response "sorry can't its 8"
me: " no its 7:59"

needless to say after we finished arguing it was past 8  :angry4:

they did tell me another location (actually closer to my house) would ship till 8:30. I fly over there like there is no tomorrow (not bad for a 12 year old 200k mile durango) and have 10 minutes to spare.

It was not cheap, but the valve body will be there by 3pm tomorrow. So hopefully here in about a week or a little more I have a good box from Cali.  :13:

The flex plate comes in tomorrow, and I had a 20% coupon at harbor freight I used on a transmission jack.

I would not have had to do that if Noah would move closer to me   :laughing7:

I think I am about done for now, just wait till the parts get here then try and take it apart and put it back together in a weekend.


So what if the flexplate is not cracked/damaged?  :icon_scratch:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 27, 2015, 08:20:51 am
always asking the hard questions I don't want to think about huh?

if it's not broken then I guess that means I did extra upgrades but with the transmission off I can verify that and move forward. Which would mean I would be back to a bearing issue... I find it highly improbable that it has a piston issue at this point, the oil would have shown something. but I can see the realm of possibility that a bearing is still messed up and just not ran enough to get metal in the oil?

let's not think about all that lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on February 27, 2015, 08:29:01 am
always asking the hard questions I don't want to think about huh?

if it's not broken then I guess that means I did extra upgrades but with the transmission off I can verify that and move forward. Which would mean I would be back to a bearing issue... I find it highly improbable that it has a piston issue at this point, the oil would have shown something. but I can see the realm of possibility that a bearing is still messed up and just not ran enough to get metal in the oil?

let's not think about all that lol

Its all good... you will be properly prepared for your new hotrod cummins motor :great:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on February 27, 2015, 08:56:02 am
That sucks about FedEx. The way I see it, if I can walk in the front door, you are open.  :violent1:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on February 27, 2015, 08:58:51 am
well fedex was still open, and was willing to ship it, just not willing to put it on the truck that was parked out front. it was a pita but I got it done.

as for a hotrod cummins, it comes down to that the truck will be sitting for a year or so while I save for it
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 02, 2015, 09:16:47 am
after all that work there was a "disruption" in CA and it was not delivered on friday  :angry4:

It is getting delivered today, and once its delivered I can call and request a refund because it did not arrive on time.

Martin said he can still get it done this week, fingers are crossed.

Flex plate comes in today, delayed because of the snow and ice. If its nice enough this weekend maybe I can drop the tranny and at least swap flex plates out. Then I could start it and verify the noise is gone. Thats the big ugly unknown right now.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 03, 2015, 08:36:48 am
Well Martin has the valve body now, and he is working on getting everything done. Hopefully he can get it done and shipped back out this week.

The new flex plate came in, and dang its heavy... this is one of the aftermarket upgraded versions that is heavier than stock. Hopefully it not only fixes the knock but avoids any future issues with the flex plate.

I was thinking about it some... and he told me he hydrolocked the engine at least once.... and I know that was the #6 cylinder from the bad injector. I also know from the craigslist posting that he liked to haul heavy loads.... so what if he was hauling a heavy load with a bad injector that started dumping fuel to cause the hydrolock? The engine would be fighting itself and fighting to pull the load. I Wonder if that would put enough stress on a flex plate to crack it?  :icon_scratch:  :dontknow:

thats about the only theory I have... its that or he just pulled too much shit and it was more than the flex plate could handle.

at any rate hopefully I get parts back in next week and I can start working on putting it back together the week after. Spring break next week and I have the kids... I don't think I will get much time for wrenching.  :headbang:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on March 03, 2015, 10:02:23 am
Good detective work. Hope you're right.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 06, 2015, 11:40:00 pm
torque converter shipped today, valve body ships Monday  :dance:

Sunday I am dropping the tranny and swapping the flex plate, maybe in a week or two if can be road worthy again, but hopefully by late Sunday I know If the problem is fixed.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 07, 2015, 11:04:45 pm
I am getting ready for tomorrow and the tranny dropping party.

I have :

the pan back on
the electrical connectors disconnected
cooling lines disconnected
driveshaft disconnected

so now I need to :

support engine
support transmission
remove brace and transmission mount
unbolt transmission


unbolt flexplate
swap flexplate

test engine


Interestingly, I took a few pics of the driveshaft

you can see it compared to the rear driveshaft out of the 93.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 07, 2015, 11:11:45 pm
Awesome  :thumbsup:

Keep up the progress!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 09, 2015, 10:24:55 am
So busy rainy day yesterday.

I have to say its amazing how much easier the right tool makes a job  :evil6: ... transmission jack is so nice, even if I have to be on the ground to use it.

Had the transmission removed in probably less than an hour yesterday.

Can't see any huge obvious cracks in the flex plate, but you can see area's where it looks like things were not seating right?

Found some metal shavings but nothing huge. Adapter plate and Starter all looked good.

I have the new flex plate mounted and torqued down as per the FSM. I do have to say the new flex plate is like 2x as heavy as the factory one. Its crazy.

The Torque converter shipped out friday, I am guessing it will get here tomorrow or wed. The Valve body ships out today, so prob get here thursday.

I thought I would be cleaver and start the truck with the transmission dropped to see if the issue was fixed. Well went to try, and no power. I mean nada. I have had the batteries unplugged for a while while working on it. Tried charging one for an hour or so, no go. Took them out, yeah they are Auto Zone specials with 5 year warranty. 3 year free replacement 2 year pro rated. Bought 12/12.  :icon_scratch:  I take them down to auto zone and give them the PO number. They need to charge them before they can test... will take an hour. The fact I just charged them for over an hour apparently does not matter  :dontknow:

Go back in an hour, yeah both are bad.... but I got 2 new ones replaced under warranty.  :13:

Go back home and hook them up. Won't even try to start. Stinking park/ neutral switch. I connected the switch back up (not in the transmission). I got it to show 1st gear. pushed the piston in and it showed nothing. I can get R, D, 2, 1 but not park or neutral?

I finally pulled out the FSM and apparently it somehow completes a ground signal circuit for P and N and the starter relay?

I am going to play with it a  bit more and see if I can get it to go. I just want a quick start and rev to 1200 rpms with my fingers crossed.

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 09, 2015, 10:27:12 am
Before I headed to bed last night I pulled out the old flex plate again under better light.


I could be wrong, but it looks like there might be a small crack in the picture?  :icon_scratch:  :dontknow:


we are going out of town thursday, which means I probably won't get the chance to put it all back together before we head out of town. but maybe if the torque converter gets back in time I can at least have the transmission connected back up.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: crazzywolfie on March 09, 2015, 11:08:48 am
ya. the neutral safety switch usually pulls a ground from the transmission case. i think if you ran a wire from the sensor case to the vehicle body somewhere it should acknowledge park or neutral. even on the older trucks there is usually only 1 wire to the neutral safety switch to stop starting and the switch gets its ground from the transmission case
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 09, 2015, 11:49:47 pm
Did you run a straight edge on the old flex plate to see if its out of round?

Maybe its a little warped rather than cracked.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 10, 2015, 08:52:02 am
I did not do a straight edge, but I did lay it against the new one. It looked pretty straight so not sure.

I did figure out how to get it started last night  :angry4:  it still has the knock at 1200 rpm. It did not seem as bad as before but its still there.

So now I guess I drop the oil pan. Its just not ending with this truck
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 10, 2015, 09:03:11 am
I did not do a straight edge, but I did lay it against the new one. It looked pretty straight so not sure.

I did figure out how to get it started last night  :angry4:  it still has the knock at 1200 rpm. It did not seem as bad as before but its still there.

So now I guess I drop the oil pan. Its just not ending with this truck

Why drop the oil pan? Pull the motor while the tranny is out and save yourself some work dude  :great:...... If you feel compelled put the motor on a stand and check it out.... it is only a core at this point  :035:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on March 10, 2015, 10:01:11 am
Just need that 4 ton engine hoist you've always wanted.  :017:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 10, 2015, 10:06:07 am
thats the issue, I question if my 2 ton engine hoist can do the job? maybe without the transmission its possible?  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 10, 2015, 10:10:14 am
it can be done  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 10, 2015, 10:20:24 am
dang you did it without removing the front of the truck or the hood?

that had to be a magic trick.

Everything I see online says remove the hood and the front of the truck so its easier to pull out.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 10, 2015, 10:24:05 am
dang you did it without removing the front of the truck or the hood?

that had to be a magic trick.

Everything I see online says remove the hood and the front of the truck so its easier to pull out.

That wasn't me... I would have at least pulled the hood though.

My helper Robert took this pic at his last job.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 10, 2015, 10:31:00 am
why oh why do you have to live so far away from me?  :violent1:


I figure at this point its gonna sit a while. As soon as the yard is not a swamp the trail rig is getting pulled into the garage and loosing some heads.

I figure this project is at a stand still until I get some more cash to play.

For now I just have to plan at least 1 more trip of pulling the trail rig with the mexico ramcharger. and that means trying to fix the steering on that, as I think that will help pulling  a lot.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 10, 2015, 05:09:41 pm
when it rains it pours  :violent1:

Martin was taking the valve body for the transmission (all boxed up) to fedex. Made a stop on the way... yeah someone stole the box out of the back.

Martin is getting ready to go on a 3 week vacation, and to make matters worse apparently the 48RE valve bodys are not a dime a dozen and hard to find.

So now Martin has to find a valve body and re-work the new one.

I did ask how it looked, he said there was no bore damage but had some sticky valves from lack of maintenance. The ATF fluid did not look like it had ever been changed. Other than that he said he did not see any major issues with it and it should be ok for a while.

He did mention that a blown head gasket can sometimes cause a knock if its blown between cylinders and not a water jacket?

I might pull the  head... can't hurt before pulling the block out and would make it lighter to pull the block.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 10, 2015, 05:36:57 pm
when it rains it pours  :violent1:

Martin was taking the valve body for the transmission (all boxed up) to fedex. Made a stop on the way... yeah someone stole the box out of the back.

Martin is getting ready to go on a 3 week vacation, and to make matters worse apparently the 48RE valve bodys are not a dime a dozen and hard to find.

So now Martin has to find a valve body and re-work the new one.

I did ask how it looked, he said there was no bore damage but had some sticky valves from lack of maintenance. The ATF fluid did not look like it had ever been changed. Other than that he said he did not see any major issues with it and it should be ok for a while.

He did mention that a blown head gasket can sometimes cause a knock if its blown between cylinders and not a water jacket?

I might pull the  head... can't hurt before pulling the block out and would make it lighter to pull the block.

Damn that Hurts!

Hopefully it will all get figured out.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 13, 2015, 10:05:58 pm
torque converter made it in wed before we headed out of town. that thing is heavy duty let me tell you  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 13, 2015, 10:10:16 pm
So whats the plan?

Pull the Head?

Pull The Motor?

Or just pull the motor apart piece by piece?

Sounds like you might as well take the plunge and pull the whole thing unless you think you can rebuild it in the truck
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 13, 2015, 10:16:54 pm
Going to pull the head and that will tell me if I have to pull the block or not.

But I figure at this point once the head is pulled I will do 1 of 2 things... either a between the frames rebuild or a pulled out rebuild.

If I can do it between the frame then it will be cheaper, and won't require new pistons but we shall see.

I know Noah said get a long block, but I rather know what parts are in it... even if that means I don't get a warranty.

Warranty is only as good as those who back it up. :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 13, 2015, 10:25:30 pm
Going to pull the head and that will tell me if I have to pull the block or not.

But I figure at this point once the head is pulled I will do 1 of 2 things... either a between the frames rebuild or a pulled out rebuild.

If I can do it between the frame then it will be cheaper, and won't require new pistons but we shall see.

I know Noah said get a long block, but I rather know what parts are in it... even if that means I don't get a warranty.

Warranty is only as good as those who back it up. :laughing7:

I replaced one Piston and One set of Piston rings in a 1946 CJ-2A 4 cyl by pulling the pan and head. Popped the piston and rod out the top with a piece of rebar. Stuck it all back together without a torque wrench or a idea of what i was doing. It kept running till my brother blew the rear axle  :violent1:

I say go for it  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 14, 2015, 08:28:08 am
It will either need one new piston/rod assembly.... or a crankshaft is the worst case scenario, if the rod/bearing ate it up.... best case scenario it is a wrist pin/piston issue only and the connecting rod and crank will be fine   :thumbsup:   If the crank is no good the motor will need to be pulled IMO... if it just needs #6 piston it certainly can be done in the truck
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 14, 2015, 08:50:27 am
I would agree with all of that... but I also think If I go i. and replace 1 set of rings I should go ahead and replace them all... replace the rear main as well, and get a valve job?

if your in there and it's tore apart why not?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 14, 2015, 09:31:05 am
I would agree with all of that... but I also think If I go i. and replace 1 set of rings I should go ahead and replace them all... replace the rear main as well, and get a valve job?

if your in there and it's tore apart why not?

eh... its a cummins... not even broke in yet.... fix the knock and have the head cleaned up at the machine shop, reset valve lash and be done. If you plan on overhauling all of it just pull the motor ... my 2cents... YDMV
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on March 14, 2015, 09:52:48 am
Ok I give up, what is YDMV?

You Dig Me Vern?    :icon_scratch:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 14, 2015, 09:56:54 am
if that's what you say then that sounds like a plan... cheaper too
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 14, 2015, 12:20:57 pm
Ok I give up, what is YDMV?

You Dig Me Vern?    :icon_scratch:
Google Says:
Your diabetes may vary

 :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 14, 2015, 01:07:04 pm
your dodge may vary? :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 14, 2015, 10:33:43 pm
your dodge may vary? :dontknow:

we have a winner   :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 15, 2015, 11:57:26 am
we have a winner   :thumbsup:

Noah Is becoming hip with the young kids and all their acronyms,
Pretty soon he will be saying YOLO,LMAO, etc etc  :laughing4:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 16, 2015, 08:22:30 am
Just wait till you get your next invoice from him.... you won't be able to understand what he is charging for  :evil6:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on March 16, 2015, 12:13:25 pm
Just wait till you get your next invoice from him.... you won't be able to understand what he is charging for  :evil6:

 :BangHead:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 22, 2015, 09:17:53 pm
Ernest was up here getting parts for my dakota he is trying to sell.

We fired up the cummins real quick and he poked around. He heard the sound but said he thought it was coming from the head area, and not the block.

So that means I will proceed with my plan to pull the head next, but it has to wait as the 93 has to get finished.. and then I think my parents are next in line for replacing their worn out struts  :confused2:

I might make a night of pulling the head just so I can try to learn more... hate not knowning  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 10:03:08 am
Ernest was up here getting parts for my dakota he is trying to sell.

We fired up the cummins real quick and he poked around. He heard the sound but said he thought it was coming from the head area, and not the block.

So that means I will proceed with my plan to pull the head next, but it has to wait as the 93 has to get finished.. and then I think my parents are next in line for replacing their worn out struts  :confused2:

I might make a night of pulling the head just so I can try to learn more... hate not knowning  :laughing7:

It is probably the piston kissing the combustion chamber due to a f'ed up wrist pin... seriously... if it is running on all 6 cylinders it is NOT the head.....  :violent1:

you can however pull the valve cover a and check valve clearance... that would be a plausible ticking sound if the adjustment is wayyy off....

pulling the head is no easy task... it is also easier to have the head on for motor removal due to built on lift points.....

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 10:09:22 am
Ernest said he heard it missing even at idle... I don't know diesel's well enough to be able to tell.

I could see the wrist pin being the cause of it all, just hope its not screwed up too much stuff in there yet.

Its not a ticking sound, its definitely a knock.

I have no doubt pulling the head is a royal PITA, just from shear size and weight if nothing else.

I have time to think on how to proceed, the long list of projects lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 10:31:21 am
Ernest said he heard it missing even at idle... I don't know diesel's well enough to be able to tell.

I could see the wrist pin being the cause of it all, just hope its not screwed up too much stuff in there yet.

Its not a ticking sound, its definitely a knock.

I have no doubt pulling the head is a royal PITA, just from shear size and weight if nothing else.

I have time to think on how to proceed, the long list of projects lol

If it is missing then the piston hit the valve... again very likely from rod bearing or wrist pin failure
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 10:34:15 am
If it is missing then the piston hit the valve... again very likely from rod bearing or wrist pin failure

As far as screwed up stuff in there, well it is a lost cause... it is time for a new long block dude... why tempt fate when you know it can bite you in the ass ... 2cents  :035:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 10:38:43 am
As far as screwed up stuff in there, well it is a lost cause... it is time for a new long block dude... why tempt fate when you know it can bite you in the ass ... 2cents  :035:

If you absolutely have to know if it will be fixable....PULL THE MOTOR... PUT MOTOR ON STAND... THEN Take all pieces that aren't f'ed to the machine shop.... plan on a new crankshaft (maybe fixable), 1 connecting rod/piston assembly , all new bearings everywhere and a couple of valves..

You already have the transmission out.... the hard part is done LOL
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 10:45:52 am
Yeah I am sure I will end up pulling it, as you said with the transmission off the hard part is done.

Now I have to find an engine stand to support that beast. Then... yeah tear into it some and see what I see. Why not the cost of that is my time, and I am a curious being that enjoys learning.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 10:58:06 am
Yeah I am sure I will end up pulling it, as you said with the transmission off the hard part is done.

Now I have to find an engine stand to support that beast. Then... yeah tear into it some and see what I see. Why not the cost of that is my time, and I am a curious being that enjoys learning.

http://www.summitracing.com/parts/sum-918014/overview/

something like that will do it.... remove accessories and manifolds before mounting it up to shave as much weight as possible.  Dont forget to remove the flexplate 1st too as it will cause trouble getting the crank out later
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 11:02:10 am
if you pull the valve cover to check valve lash you will find that the adjustment on the afflicted cylinders valves will be way off.... this is because the valve is bent and not seating fully

edit... check lash when both valves are fully closed and piston at tdc compression
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 11:03:52 am
thats not a bad price. and yeah remove all that stuff before pulling it out probably.. help with the weight of the sucker to pull out as well.

then removing the radiator, intercooler, and all that fun stuff up front as well. my 2 bay garage area will be turned into a 1 car garage to deal with all the parts lol


Hmm I had not thought about checking the lash and seeing how bad it is. I know its the 6th cylinder... that would be a easy thing to check.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 11:06:50 am
thats not a bad price. and yeah remove all that stuff before pulling it out probably.. help with the weight of the sucker to pull out as well.

then removing the radiator, intercooler, and all that fun stuff up front as well. my 2 bay garage area will be turned into a 1 car garage to deal with all the parts lol


Hmm I had not thought about checking the lash and seeing how bad it is. I know its the 6th cylinder... that would be a easy thing to check.

normal is about .010 intake & .020 exhaust... abnormal will be more like .050"+... especially if all other valves seem close to right
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 11:11:31 am
If the valves are bent, I should be able to hear it leaking out if I do a leak down test and listen closely.

Not hard to pull the injector with the cover off... well not hard relatively... that #6 its a PITA for anything but it could be worse.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 11:18:33 am
If the valves are bent, I should be able to hear it leaking out if I do a leak down test and listen closely.

Not hard to pull the injector with the cover off... well not hard relatively... that #6 its a PITA for anything but it could be worse.

yes a leak down will tell you a lot... however I would do all of this investigation with the motor on a stand. It will make much simpler work and you know thats where this is headed.

A good rule is that if it can be taken apart more easily later, and it doesn't interfere with pulling the motor ... leave it for a time when the part (like a pia injector) is easily dealt with

here is another nice stand...

http://www.summitracing.com/parts/sxt-8259

it has better reviews than  the summit brand and is more storable
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 11:20:54 am
Storability is good.

and yeah it would be a lot easier out of the truck. I am itching to work on this thing, I even managed to get a little $$ put back for repairs... but not long block $$. I just have too many projects. I need like 2 weeks off work to catch up on projects so I can work on it lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 11:26:53 am
Storability is good.

and yeah it would be a lot easier out of the truck. I am itching to work on this thing, I even managed to get a little $$ put back for repairs... but not long block $$. I just have too many projects. I need like 2 weeks off work to catch up on projects so I can work on it lol

I hear you... I am still recovering on the Dodge fund  :confused2: ..... you might save some good money over a long block  :dontknow: ...It all depends on what you find in there

Here is one more stand. I think I need this one  :great:

http://www.summitracing.com/parts/rnr-5150470/overview/

edit: better deal here - >  http://www.amazon.com/JEGS-Performance-Products-80042-Engine/dp/B007VRESH6/ref=sr_1_10?ie=UTF8&qid=1427127480&sr=8-10&keywords=engine+stand

edit edit: this is getting out of hand -> http://www.amazon.com/gp/product/B00JV8BQWI/ref=pd_luc_rh_sbs_02_02_t_img_lh?ie=UTF8&psc=1
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 11:32:01 am
http://www.harborfreight.com/2000-lb-capacity-foldable-engine-stand-69521.html

Not sure if the quality is any different... but shipping and price is.

Yeah thats why I want to dig down into it first. I need to save $$ where I can to make this come out a decent deal in the end.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on March 23, 2015, 11:35:48 am
http://www.harborfreight.com/2000-lb-capacity-foldable-engine-stand-69521.html

Not sure if the quality is any different... but shipping and price is.

Yeah thats why I want to dig down into it first. I need to save $$ where I can to make this come out a decent deal in the end.

ok you win by like 10$ if you count sales tax... but you still have to go get it... I am a free shipping whore ( I dont go anywhere unless absolutely 100% necessary)  :headbang:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on March 23, 2015, 11:40:48 am
well harbor freight is like 1.5 miles from me... its not a 3 hour trip like it is for you.

But yeah, free shipping is king. Got to love Amazon for that.

95% of my parts for the trail rig rebuild came from amazon. If they had sold the injectors for the cummins I would have prob bought those there too lol.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on March 23, 2015, 02:38:13 pm
I was looking at the reviews for the HF engine stand.  The one major complaint is that it won't fit between the legs of the engine hoist. Might wanna get measurements of the other stand to see if there is a difference.  That would be a pita if you couldn't load it  straight onto the stand.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 29, 2015, 11:07:20 pm
Well after I got home from work today I changed and went to play in the garage.

Took me 2 hours to get the injectors out and a bit more... thats not too bad I think.

It then took me about 1.5 hours to get the exhaust and turbo out... man that was a chore... who knew heater hoses could be such a PITA.

After that I worked on the fuel assembly and fan shroud. The FSM said remove the fan... but I have not yet  :evil6:

A few wires, move the alternator and then a few head bolts... and a few more. I think there were 26 total? about 3/4 of them I got with the impact but still. it was a pain.

The head looks ok, Cylinder 1 has a bit more carbon than the rest.

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 29, 2015, 11:10:25 pm
There are no holes in any piston... so thats a good thing  :13:

number 6 got some oil and antifreeze from the head pull, so it is a bit wet.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 29, 2015, 11:11:53 pm
The 6 cylinder seems to have some carbon/ junk at the top of the hole, and it has some stuff that looks like a scuff/ mark... but its all smooth?  :tard:  :dontknow:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 29, 2015, 11:15:40 pm
So I wanted to look at the 6 cylinder more, so I got under the truck and turned the crank some. It was not as easy as I thought it would be, but got it turning.

No sounds and looked ok. Then when the 6 cylinder was at the bottom of the stroke... had a sound. and... if you do that 1100 RPM I would bet its the knock I heard. Strange thing is it did not make the sound with the head on?  :dontknow:

So now its either the write pin as Noah has stated or the arm bearings?

Means I need to drain the oil, drop the pan and see what I can see.

I need to get input from Noah and Ernest, but my understanding is you can't re-ring these pistons... and if I have to take the piston out to fix the wrist pin... does that mean I need to just do a new piston or?  :dontknow:

its at a stopping point for now. I have to work on my folks car sat, so maybe either after that or sunday I can work on the truck some more... have to research a bit.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on April 30, 2015, 07:15:12 am
So I wanted to look at the 6 cylinder more, so I got under the truck and turned the crank some. It was not as easy as I thought it would be, but got it turning.

No sounds and looked ok. Then when the 6 cylinder was at the bottom of the stroke... had a sound. and... if you do that 1100 RPM I would bet its the knock I heard. Strange thing is it did not make the sound with the head on?  :dontknow:

So now its either the write pin as Noah has stated or the arm bearings?

Means I need to drain the oil, drop the pan and see what I can see.

I need to get input from Noah and Ernest, but my understanding is you can't re-ring these pistons... and if I have to take the piston out to fix the wrist pin... does that mean I need to just do a new piston or?  :dontknow:

its at a stopping point for now. I have to work on my folks car sat, so maybe either after that or sunday I can work on the truck some more... have to research a bit.

you might be able to put in a new piston and rod assembly if the crank shaft looks ok... if the rod bearing ate up the crank its all over  :035:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 30, 2015, 07:18:57 am
yeah  I figure I am dropping an oil pan this weekend ... should be interesting
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 30, 2015, 11:16:46 am
So Noah,

just to clarify... your saying, if the crank is good to just get a whole new piston/ ring/ wrist pin/ rod/ bearings

Hone the cylinder and throw it back in?

Don't touch anything else in the bottom end.

What about the head? Do I need to do anything to it besides scrap some carbon off?

Plans changed for tonight so I am going to see if I can get the piston out tonight. should be interesting
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on April 30, 2015, 01:05:05 pm
So Noah,

just to clarify... your saying, if the crank is good to just get a whole new piston/ ring/ wrist pin/ rod/ bearings

Hone the cylinder and throw it back in?

Don't touch anything else in the bottom end.

What about the head? Do I need to do anything to it besides scrap some carbon off?

Plans changed for tonight so I am going to see if I can get the piston out tonight. should be interesting

Yeah if the rod bearing is still tight on the crankshaft just replace the 1 Rod and piston assembly and bearings for that rod ... as far as the head goes I would have it checked out for flatness and install new valve seals and clean the valves at the machine shop. It is certainly a risky repair but if you can definitely nail it down to #6 cylinder only then it would be worth a shot... if the rod is loose on the crank due to worn bearings it should probably have ALL the rod bearings changed.... That can be done without pulling all the pistons by removing only the rod cap and "rolling" new bearing shells in.... #6 rod journal should be measured for out of round and ensure that  it is within factory tolerances before making this decision... it will likely still need a rod and piston for #6 if that is the path you choose. The scuffing you see on #6 cylinder is likely also present on the piston
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 30, 2015, 11:18:47 pm
Well S**T

 :angry4:

 :violent1:

I know what the problem is now... and its not pretty.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 01, 2015, 07:26:45 am
damn it... to be expected though  :'(
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 01, 2015, 07:32:13 am
yeah... now I pull the block and the crank and see if it can be polished and turned down. Then I can get 10 over bearings... maybe 20 over's

then go back to the new piston and rod.

Question is... if the engine is out and the crank is out... do I leave it at that?

I don't want to be a cheap bastard... but I don't have the 5k to spend on a long block.. if I did I would have already done that lol.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 01, 2015, 07:36:26 am
I would have all the bores honed (should be ok at std bore) .... new pistons and maybe one new rod(machinist will verify)... replace all bearings
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 01, 2015, 07:41:28 am
If I am going that far, might as well get the block dipped and alined, make sure its all good and straight.

but yeah was thinking that... so there is 1500 for the rebuild kit. then start adding on the machine shop services lol. still 2200 is easier to swallow than 4800. And it will be good character building to try and build a cummins  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 01, 2015, 07:58:47 am
If I am going that far, might as well get the block dipped and alined, make sure its all good and straight.

but yeah was thinking that... so there is 1500 for the rebuild kit. then start adding on the machine shop services lol. still 2200 is easier to swallow than 4800. And it will be good character building to try and build a cummins  :laughing7:


yep just keep it clean and make sure you have the necessary service manual to set up all the timing and correctly torque all bolts... it is a bit different than a small block, but not rocket science  :great:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 01, 2015, 08:10:54 am
yeah I have my FSM... I won't go into an engine without one.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 02, 2015, 10:16:26 pm
well about 6 hours from start to stop today. Too much of that dealing with the stupid fan clutch  :violent1:

It is out of the truck and completely broke down. That is a job and a half lol


So the #1 and #6 had broken rings, the first ring which I think is the compression ring if I recall. They have slight scoring which means they need to be bored.

The #6 rod got hot as you can tell by the color change, the crank looks to have fared better but not sure if its useable. The machine shop said they would test it for hardness to see if the heat effected it or not.

I will be taking the block, crank, and rods to the machine shop to clean test bore and all that fun stuff.

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 02, 2015, 10:17:26 pm
more pics

and I have to say, that is a wrist pin  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 02, 2015, 10:22:45 pm
So the machine shop is getting a master rebuild kit with upper and lower gaskets, rings, bearings, and pistons.

They will:

Clean, bore, hone and align hone the block. Deck if needed
Rebuild the head
check the crank, if fixable will fix
check rods for straightness and strength


Along with all this, I have a ton of parts to clean  and a few to order:

New water pump (OEM)
New Oil Pump (OEM)
1 new push rod (I messed it up)
New Injector install kit
New Fuel line gaskets
New Oil cooler (I bent the tube on mine a bit, it might be ok I have to look more)
New Condenser (its nasty looking) and seals for it
New Head bolts... you can reuse if they are not too long... but I figure I will just go ahead and get new to be safe
Assembly lube
Oil and filter
antifreeze

I miss anything?

Putting it all back together should be interesting, that thing had bolts and sensors and wires everywhere!!!!! took me like an hour to get all the electrical off of it  :confused2:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 03, 2015, 09:19:05 am
Sounds like everything to me  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 03, 2015, 11:40:00 pm
well block is loaded up in the back of a borrowed f150 to go to the machine shop.

man you should have seen the truck squat lol. I think the block and crank are about load capacity for the truck.

I got all the pistons off and have the rods with me as well so they can check them all out as well.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 04, 2015, 09:36:16 am
Dropped off, they said it should all be finished up around Thursday.

Fingers are crossed on the crank.

Now to get the other goodies ordered in.. Will have a trip to the cummins house this week I think.

Noah do you get a wholesale price on OEM stuff? lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 05, 2015, 11:34:20 am
 :angry5: :violent1:

 :angry4:

crank is bad... now I need a new crank.. those are nice and cheap
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on May 05, 2015, 03:03:18 pm
How much is it? 

I think I'm gonna stick with my gasser for awhile.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 05, 2015, 03:41:50 pm
new is $1200... trying to find a used one. my fingers are crossed.

Diesel is definitely expensive... I sure hope its worth it.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 05, 2015, 09:09:31 pm
new is $1200... trying to find a used one. my fingers are crossed.

Diesel is definitely expensive... I sure hope its worth it.

you wont regret it  :great:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 05, 2015, 09:12:27 pm
I have decided to go new on crank... hard to find a used one... it has to be 2003-2006 and those are just not really out there. Plus the ones that are just look shady.

Funny enough the local Cummins house has the crank in stock and cheaper than the after market from the machine shop.  :dontknow:

Plan is to get everything cleaned and all the parts in and start assembly on the 15th.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 11, 2015, 10:23:07 pm
Well I have the block and head home, but the rest are due to be picked up tomorrow.

They bored the block 20 over and I have a new crank and pistons as well.

I am cleaning and prepping everything I can so that assembly hopefully goes fast.

Started some of the "make it pretty phase tonight too"
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 11, 2015, 10:24:10 pm
oh forgot to mention... decided to rebuild the tranny while everything is apart. Valve body shipped out today so the tranny is at the shop getting new clutches and steels.

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 13, 2015, 11:59:00 am
Got the crank and rebuild kit yesterday... man it has a bunch of little o rings in it  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 13, 2015, 11:59:27 am
All set out and ready to start back together
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 13, 2015, 12:01:01 pm
I also have to say, that while I have not owned a parts cleaner long... its a great investment.

Sadly I now have to deal with the part that no one wants to.

Cleaning it  :laughing7:

Started draining it into spare milk jugs to take to dispose of. Need to pump some more out and deal with all the sludge on the bottom. Yuck!!!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 13, 2015, 01:55:20 pm
I have never cleaned my parts washer.... :tongue3: ....I would  hate to know what is in the bottom :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 13, 2015, 01:56:51 pm
I took my pump out and cleaned it some.. it started working better too.

Maybe I will have to bring some new cleaner and a pump with me down there.. you just have to figure out where to dispose of the old stuff.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on May 17, 2015, 07:22:10 pm
How did the engine building go?
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 18, 2015, 12:32:29 am
a very very long weekend.

I will post some pics up tomorrow.

it runs and idles good, the rings set after about 15 miles and it's not smoking.

having an issue with the TVVA thing on the transmission, so it's causing a shift issue and no OD

going to work on that more, might have to replace it... but it seems to have lots of power.

engine build went great without issues.... getting it back in.... all sorts of little issues but we got er done.

I do have a leak on the turbo oil return I have to fix.


Oh and yeah the AC is cold again too  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on May 18, 2015, 11:11:29 am
Sweet.  :thumbsup:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 18, 2015, 11:15:22 am
pics  :13:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 18, 2015, 11:16:36 am
and more.


The TVVA valve is messing up on the transmission, so no driving it until thats fixed. Going to work on it tonight.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on May 18, 2015, 02:46:27 pm
I've seen that look on Ernie before.  Its called sleep-working.   :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 18, 2015, 03:00:32 pm
that could be... I will say he was amazed at all the parts cleaning I did and he was also equally cursing my name because I did not remember how things went, or took enough pics, or labeled the bags good enough  :evil6:

But we got through it and its good. Had fun, but don't need to repeat that again


oh and for reference, anyone dealing with a cummins... DO NOT under ANY circumstance put the motor mounts on backwards and figure it out once its in the truck. Its a real PITA to fix  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on May 18, 2015, 04:13:43 pm
Yeah, I heard effing Dodge quite a few times. Became the catch phrase of the build.  Everything I took off, I kept together by group in separate containers. When we moved from the shop to his trailer, he threw it all together and said, "Oh well, we'll figure it out later.". Good thing I took a lot of pics but pics didn't capture bolt length. Lol
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 19, 2015, 07:50:35 am
Awesome work  :thumbsup:
so y'all built the motor and installed it in one weekend!   :sleepy:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 19, 2015, 08:11:42 am
Awesome work  :thumbsup:
so y'all built the motor and installed it in one weekend!   :sleepy:

yes built and installed in one weekend... I will never do that again  :laughing7:

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 19, 2015, 10:17:24 pm
well the last gremlin is dead and it's going great.

1 little oil leak to fix and it's good to go.

have 60 miles on it, have to be nice the first 100... then change oil after 500. no towing till 1000 is what I heard.

so between now and end of June I have to put 1000 miles on it. though I will say I don't think it's going to care what is back behind it with the torque it has  :laughing7:

it also looks to be getting better gas mileage than the Durango with the 4.7 in town, time will tell
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on May 20, 2015, 07:54:58 am
well the last gremlin is dead and it's going great.

1 little oil leak to fix and it's good to go.

have 60 miles on it, have to be nice the first 100... then change oil after 500. no towing till 1000 is what I heard.

so between now and end of June I have to put 1000 miles on it. though I will say I don't think it's going to care what is back behind it with the torque it has  :laughing7:

it also looks to be getting better gas mileage than the Durango with the 4.7 in town, time will tell

I am fairly certain that almost any vehicle will get better mileage than a 4.7 .... The one I used to drive was doing reallll good to get 12-13 mpg... worst I ever saw was 9-10 mpg between vegas and california... that was flat out WOT struggling to maintain 65mph ( I had to stop and drop the tailgate to do that)  :confused2:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 20, 2015, 08:12:41 am
I get 15 or so in town, 18-19 on the highway. and it's got some pep... but it ain't stock, I have HO came in it  :laughing7:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: taz_man440 on May 20, 2015, 10:55:52 am
Awesome to hear... Now, money wise was it worth it???  I would love to find something like that but that's way over my skill set.  I would also hate to see what chicken little would charge to travel to me to work on it..
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 20, 2015, 03:07:48 pm
Don't get me wrong... it was A LOT of work. But the general parts were not that hard or complicated. I had a FSM which helped a lot.

Price wise.. I would say I am anywhere between 2 and 4k under what this would have gone for off a dealer lot in fair condition. So some would say I saved 2k, not worth it.... but I have brand new injectors (4k installed) brand new engine (6k installed) and a brand new transmission (2k installed) with upgraded valve body and torque converter (1800 installed).

Now clearly the parts/ install price does not add directly to the base value of the truck. but give the choice I would much rather have this one than a stock one that will have issues.

I also added a heavy duty fuel/ water filter setup to hopefully prevent any more injector issues and make them last longer. When I get 100k miles on them I will probably pull them and get them tested and cleaned.

Oh speaking of... the other thing that helped.. I bought the tools required to pull the injectors and do some test. While you can do it without the tools, its a real PITA to do so.

Overall I am very happy. Would I do it again? Probably so... but I would not build and install an engine in 1 weekend again  :evil6:

Am I happy with the truck now, I am ecstatic with the truck. Its like having the power of the ramcharger is a quieter and more fuel efficient version  :headbang:

Let me tell you, I can't speak for earlier cummins, but this common rail version... it has some balls!!!! it will push you back in the seat and keep on going.  :great:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: taz_man440 on May 20, 2015, 09:18:45 pm
That's great!!  I would want a 4x4 version to tow with.  I know it would make for better towing off road to the camp spot or even as a recovery vehicle... But at least you know whats been done to the truck now.  Just picking one off the lot you really have no clue....
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 20, 2015, 09:21:02 pm
4wd would be great, but sometimes you just play the cards you were dealt.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: taz_man440 on May 20, 2015, 10:01:06 pm
 :13:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 21, 2015, 11:03:38 pm
Drove it the last 2 days, its doing good... average 18.4 mpg for fuel economy... I can't complain about that at all.

The stereo needs a bit of help, but I have another one I can put in there until I can afford the one I want.  :headbang:

The next things to do are brakes, shocks, and check all the front suspension.

The brakes seem good, but have a bit of a warp feeling to them. I need to check it all out good.

Oh I also need to move my brake controller over, this has one, but I don't like it as much as mine so I will replace it.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on August 16, 2015, 03:23:53 pm
Finally broke down and got some new tires... went with some Michelin Defenders, the brand new ones they just came out with.

Driving it home, quieter, smoother... and my alignment issues are gone  :13:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on August 27, 2015, 02:24:44 pm
Found a new bed for the truck, its not abused at all... its at the body shop getting worked on now.

I also bought a new grille (paintable with honeycomb inserts) and a new back bumper that is also paintable.

Body shop is going to paint  it all to match the truck when it goes in to get the hail damage fixed.

Also ordered new tie rod ends, the driver side were shot. I will get them in soon, I still have upper ball joints on the list.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on November 01, 2015, 04:47:57 pm
so I had a blast this weekend working on the cummins.

Replaced the upper control arms and lower ball joints on the front as well as new shocks all around.

I had to do some front brake pads too as the rear side was about gone!!

it drives a lot better now, and rides a bit better too.

took about 9 hours of work with a few trips to the parts store. It would have been faster but i managed to bend my ball joint tool and did not realize it for a while... that really slowed down progress lol

Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectM880 on November 02, 2015, 06:10:34 am
At this rate you basically built yourself a new truck  :thumbsup:

That thing is going to tow like a beast!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 05, 2016, 09:40:02 am
Well it finally came time. The truck is at the body shop for a 4-5 week make over.

Lets see how it looks after this.

Its strange to not have it right now though.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on May 05, 2016, 05:52:48 pm
Haven't seen it in forever. Gonna need some before and after pictures.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on May 05, 2016, 09:24:56 pm
right now it looks like a grapefruit  :violent1:
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on June 15, 2016, 02:34:20 pm
So I have been without her (I guess its a her?) since May 2nd.

The roof has been replaced and all dents removed. Its primed and clean and ready for paint... except... the new hood and front bumper are MIA.

They shipped June 6th, but never showed up. They are working to either track them down or get new ones sent out.

http://www.cervinis.com/02-08ram-srt-hood.html

the hood and front bumper are those shown in the link above. I think it will look awesome when its done!!

If I ever get it back.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on June 15, 2016, 10:52:16 pm
That will look awesome!!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on June 22, 2016, 01:27:22 pm
The Hood and front bumper are in as of Monday!!!! so hopefully paint is going on this week and I get her back next week sometime.

Fingers are crossed.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on June 25, 2016, 09:46:39 am
The Hood and front bumper are in as of Monday!!!! so hopefully paint is going on this week and I get her back next week sometime.

Fingers are crossed.

So when are the compound turbos and tuner showing up for this bastard SRT cummins truck LOL
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on June 29, 2016, 09:32:44 am
turbo's show up when someone else helps pay for them lol

tuner is already in the works.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on June 29, 2016, 10:05:10 pm
turbo's show up when someone else helps pay for them lol

tuner is already in the works.

INSTALL EGT GAUGE 1ST
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on June 30, 2016, 10:52:20 am
oh heck yeah, getting a full gauge setup... pyro, trans, and probably a 3rd just not sure which one I want yet. But then again I might go digital so I can get it to go into the data logger. Not sure yet.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on June 30, 2016, 12:57:44 pm
oh heck yeah, getting a full gauge setup... pyro, trans, and probably a 3rd just not sure which one I want yet. But then again I might go digital so I can get it to go into the data logger. Not sure yet.

pyrometer, boost and trans is a good combo. Some people like knowing fuel pressure but it is a bit overkill for a mild 3rd gen IMO.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on June 30, 2016, 01:00:27 pm
yeah I am not worried about fuel pressure. more interested in trans temp and the turbo. As long as those 2 are happy the truck will be happy.

Can't wait to see it all back together with the new hood and number and whole new paint job!!!

then I have to take it to dodge for the air bag recall.

After that its new carpet and getting the front seats fixed, probably the steering wheel finally. then it will be good to go
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on June 30, 2016, 01:03:32 pm
yeah I am not worried about fuel pressure. more interested in trans temp and the turbo. As long as those 2 are happy the truck will be happy.

Can't wait to see it all back together with the new hood and number and whole new paint job!!!

then I have to take it to dodge for the air bag recall.

After that its new carpet and getting the front seats fixed, probably the steering wheel finally. then it will be good to go

Awesome... You want regret a single dime LOL
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 15, 2016, 10:19:40 am
I see the light at the end of the tunnel!!!

The fog lights were broke so I ordered replacements for those. He should have the front bumper on today... I am guessing the hood and grille too, so early next week I can pick her up!!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 21, 2016, 08:52:07 am
I got her picked up last night. I will get some pics today... its AWSOME!!!!

the only down side is that they did not re-install my gooseneck hitch in the new bed. So now I have to cut a 10" square myself to get that installed.

I called around and it does not seem like anyone will touch those now days. They want to install the new style, but I am not going to pay $800 to upgrade to the new style when the old one works just fine.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: SixGun on July 21, 2016, 07:39:23 pm
So what's the new vs old style?

I got your pic and it's freaking awesome looking!!

Need more pics ASAP!!!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 25, 2016, 04:31:24 pm
before
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 25, 2016, 04:36:18 pm
after
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 25, 2016, 04:36:52 pm
it now has zero chrome... painted front and rear bumpers, new bed, new fiberglass hood.

good progress!!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: ProjectPW on July 26, 2016, 08:55:52 am
it now has zero chrome... painted front and rear bumpers, new bed, new fiberglass hood.

good progress!!

the dodge emblem is chrome... Looks great!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on July 26, 2016, 08:57:49 am
well its the only place on the truck that now says dodge.. and I guess technically the Cummins Emblem is chrome too.. but that is an acceptable amount of chrome I believe.
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: KeystoneSmooth on August 01, 2016, 12:48:37 pm
Looks great!
Title: Re: 2005 Dodge Ram 2500 Cummins 2wd
Post by: rjtx667 on April 03, 2017, 10:18:58 pm
So trying to tweak a few things to get ready for the moab trip


Installed a new alpine radio with a backup camera. So much better than stock!!

Also just got the onboard air compressor for the air bags installed, that will be nice to have again!!

I need to change the fuel and water seaperator filters as well as change the transmission fluid before the trip, otherwise i think its about set

I did just do a full brake job on my trailer wirh repacking the bearings so it too is ready to roll!

Less than a month away