Ms Piggy. Black and Blue!

[chuzie]

Ur nuts. I can't believe u r doing this.

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[broncosbybart]

Zep industrial degreaser cut with water and put in Sharon's garden sprayer....

She's real happy about it.

Chuzie, I had to clean it before I tore it all apart. I can't leave anything in one piece.

[snipes243]

I will have to try that

[broncosbybart]

Ok, so I haven't updated this thing in forever. I haven't done anything either, so there. However, it wasn't up to date when things got busy here.

Due to Jay's prodding, here is a progress report.

Like everything else I touch, I can't leave anything well enough alone. The amount of sludge on the exterior of the motor had me concerned, so I stripped it down.

A paper copy of the Cummins manual is around $150. After a bit of digging, I found a huge PDF of the thing online and downloaded it. It is like 500 pages and is detailed but easy to follow for the most part. Armed with a few nights worth of reading, I tore into the engine and now it is scattered in a thousand pieces on my work bench, on the floor, and across the garage...

The 4btswaps forum has been a valuable resource, but I haven't found anything on there detailing a tear down and rebuild of these engines. For those that care, my thread there can be found here:

http://www.4btswaps.com/forum/showthread...ord-Bronco

But, here are a few pics of the teardown.

[broncosbybart]

You might be able to tell from the one pic above, but if not, the alum timing housing was cracked right where the infamous 'killer dowel pin' resides. I am going to have it welded up. Between that and the loose valve cover on cylinder #1, those were the culprits to the layers of extinct dinosaur ramains coating the outside of the engine.

I threw in a pic of the push rods stuck through some cardboard. That is a handy trick I learned years back to keep them organized. Works great and the price is right!

Here are some more pics of the teardown. Everything else looked good. The rod bearings had some wear on the upper bearing. Talked to a buddy I ride bikes with who works for Cummins and he said that is normal and that some guys cheat and just rotate the bearings 180 degrees and reuse them. No thanks.

Getting the pistons/rods out was made easier by my high dollar 2x4. Fit perfectly in there. Removing the crank turned out to be about the hardest part. That friggin thing weighs as much as I do!

Overall, the engine was super easy to take apart. Almost reminded me of a Briggs motor, with the flat tappets down in the block like that. At least this engine uses an oil pump instead of a slinger for lubrication.. My thought as I finished the tear down was that this engine doesn't really appear to have been designed for performance, just function. Nothing is super fancy or involved. Just big and heavy, kind of like the rest of the truck.

[broncosbybart]

Got the block cleaned up and honed (deglazed) the cylinders for new rings. No pics of the process, but it is basically taking the shine (glaze) off the cylinder walls so that the new rings will be able to seat and break in correctly. Plenty of info on the old youtube if you need info on the process.

[chuzie]

Well done. Let me know when i can drop mine off for a rebuild too.

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[broncosbybart]

No time soon, that's for sure! I want to get my truck done!!!

Remember my cracked timing housing? It is cast aluminum. I don't have any way to weld it up.

Meet Jim (Cheech) Garde. He is the man with a plan. One time I rolled up to his workshop and there was a bobsled sitting in the bed of his pickup. Went inside and there was one sitting in his shop. What the heck???

Cheech did a LOT of work on the US bobsled teams sleds under Bodine. It was wild to see a couple of sleds that would be competing in the US olympics!! For the last olyimpics, BMW was involved with the 4 man sleds, but Cheech is still very much involved in the 2 man sleds. His background is NASCAR (Winston Cup) for the old-timers. He quit that about 10 years ago to go out on his own doing custom fab and machine work. His work is amazing- top notch!

He went to work hogging out the aluminum housing around the crack using an assortment of die grinders and carbide bits. After that, he used a propane torch to try and boil the engine oil out of the crack as best he could. Then it was on to the work bench and the TIG machine. The end result is a super strong fix that should be fixed for good! I just had to grind down the built up weld and clean up a few of the bolt holes and the dowel pin hole. Better than new!

[broncosbybart]

A few more pics of his shop along with a crazy competition boat of some nature. It has an insane BBC in it. The drive line is bolted to the harmonic balancer, hits a gear box near the drivers seat, and then the prop shaft goes from that gear box, back underneath the engine, and out toward the back of the hull. It is a prop boat. I thought it was an old school jet boat but it isn't. Cheech was doing some work on it for a 300 mile race coming up in a few weeks. I've never seen a boat quite like it.

[chuzie]

You are a very interesting individual bart.

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