A pushrod being an inch lower than the others is quite significant...............something is definately amiss.

 

Welppp i rolled all my pushrods across a pane of glass and all the pushrods are straight so ill chaulk that dropped front rod up to my own error during removal

i pulled my number 1 piston completely out and realized the "flakes" i saw on the top were actually dents

here she is







I checked the connecting rod and the rod bearings, the rod bearings were slightly scarred but the CR was good so ill throw a new set of rod bearings in when i pull all the pistons to hone out the cylinders






the cylinder wall on the number 1 cylinder has a few scratches but im hoping honing it out will clean it up, and the whole set are getting new piston rings



the crazy part is that even with the extensive damage to the head of the piston the damage on the bottom of the head was almost unnoticable





So my best guess is that the chunk that came out of the edge of the piston must have been bouncing around inside the cylinder and managed to tear up the piston top without damaging the head or cylinder walls

Im going to install
-a new #1 piston and connecting rod
-all new rod bearings on all 6 connecting rods
-hone all 6 cylinders
-new rings in all 6 cylinders
-new head gasket
-and some ARP head studs

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and while everything is torn apart im going to do the freeze plug kit and throw on some new oil return lines and get the oil return plug for the front oil port and new gaskets

 

make sure you dont have any cracks around your valves clean them and check them they can be very small I dont see how it only beat the hell outta the piston and not the head? I can see some dents on the edge of the valve seats. The pic of the cylinder wall looks failry scared and if its to scarred your wasting your money, do you have a telescoping guag and a micrometer to check specs on your cylinder wall?

 

Your a hell of a "go getter" with your mechanical skills bro. BTW Thank You for your service.

 

Welll i tried to hone out the number 1 cylinder but there were still slight channels in the wall and a chip missing so im pulling the engine out tomorrow morning and she is going to a shop to get the cylinder bored and sleeved back to stock specs... $200 and a 2-3 day turn around... so hopefully by the end of next weekend to early week she will be fully reassembled and back on the road

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Thanks

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did some more prep work for pulling the engine today. i got everything on the exhaust side of the engine removed and marked and im about 3/4 of the way through unhooking everything on the drivers side, all ive got left is one loom of wires and the starter then take out the front cross member and pull the bloCK TOMORROW morning, strip the rest of her innards and take her on down to the performance shop and let them work their magic

started on cleaning up some of the goodies and getting everything looking all fresh and sexy like

 

Might as well because you got her all torn apart man! you gonna paint the block green too! Glad they have a fast turn around... Hows the head though?

 

I'm curious what can looked like. These motors eat cams like no ones watching


Sent from my DROID RAZR using Tapatalk 2

 

Wow it seems your having a whole lot of bad luck with this truck lots of money but was it leaking antifreeze or anything it looks like a soft plug up in that picture but glad to see someone is actually doing the work the self and getting **** done good job on it and yes please put up pic when done I'm excited to see what it looks like

 

Yeah, it sucks that it happened that way. BUT, he's gonna have a fresh engine, and anything that went wrong will be repaired AND anything that was about to go wrong is also addressed. Ya gotta admire his tenacity..............

 

well i finally got my engine back in and bolted up to the trans today so heres an update on everything thats happened since

got all my goodies... ending up getting two new pistons+rods bought from a fellow diesel forum guy, all new gaskets for everything, freeze plugs, head studs, get my head milled and the block cleaned up







once i got the block and head back everything got cleaned, taped off and given a good 4/5 coats of Grabber Green engine paint and all the accesory parts got shot with a coat of black... should help liven up the engine bay a little bit






Then once i finally got all the parts i needed for my rebuild (which took wayyyy too long due to UPS F%&King stuff up in the shipping proccess) i was able to start putting everything back together



kept pluggin away piece by piece until she was all ready to drop back into the bay







Im REALLY happy with how the black and green all turned out

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The heart going back into the beast








AND THESE BAD BOYS WILL BE GOING BACK IN TOMORROW



Goal is to have her buttoned up by the weekend and inital run on Monday

Not too bad for a 22yr old Military boy in a buddies backyard under a $50 walmart canopy with tarp walls and a few sheets of plywood for a "floor".. gotta work with what ya got

have to say without a doubt that my chilton haynes manual and everything i learned from lurking around diesel forums has def helped with this process