CUCV-II, South Florida Rebuild

[Stonepicker1]

1999 CUCV-II, 1-1/4 ton, 4X4, Type B, Cargo Truck/Personnel Carrier with 6.5 turbo and only 16,000 miles.

My New Year Resolution: To start rebuilding the CUCV II that I bought back in Nov of 2008 from MacD*LL AFB in Tampa, Fl. I deployed to Ir*q for a year and now its time to
First off, I thought it may of been bad PMD or maybe a bad injector pump(by GL pictures) but after picking it up and looking it over I saw a lot more issues. Motor mounts were missing bolts, oil pan was loose and missing bolts, starter missing to name a few.
I worked on it all day today. I removed all the glow plugs to release any compression and tried to turn the engine over by hand. The crank would not turn at all. So if I wanted to pull the engine I would have to pull the transmission with it also. Well I looked at that and it was a lot of work. So I dropped the oil pan to see if I could fine something that would make the engine to be seized. Well it took some time to get the oil pan off and out of the way(almost thought about dropping the front axle). But I did find something, on the front part of the crank, the rod bearing took a sh*t. I had a hard time getting the caps off, but when I did I was able to turn the engine over and remove the flywheel bolts.
I'm almost ready to pull the engine, just have to disconnect the power steering lines and the oil cooler lines.

Here are some pictures, more to follow.....

 

[Stonepicker1]

Here is the the New, GEP 6.5 engine that will be going into the truck. I bought a new HO water pump and new Injectors for a total of just over $6,000 shipped. I have new glow plugs. Looking for a new or rebuilt injector pump with PMD.

 

[Stonepicker1]

New engine on stand.

 

[Stonepicker1]

Finding out why engine won't turn over. more pictures to come.

 

[Stonepicker1]

Pictures of what cause the engine to be locked-up. look at the rod bearing on the crank , it jambed in between the piston rod and the end cap.

 

[Stonepicker1]

Pictures of the rod bearing after I got the end caps off. PITA to get off.

Now I'm almost ready to lift the engine out. But now I need some sleep.

 

[Cucvnut]

Cool man ! I love the newer truck I wish we could get them

 

[1986Blazerk5]

While you have the new engine out i would install a Block Heater

The truck will be cool cant wait to see

 

[Stonepicker1]

While you have the new engine out i would install a Block Heater

The truck will be cool cant wait to see

The new engine has a new block heater already installed. Thanks.

 

[NDT]

Very much appreciate your photo-documenting this. I can't imagine how many hours you will have in this after the additional work associated with the air conditioning and turbocharger. But the time and expense will be well worth it to have this bad azz truck with the dream Optimizer 6.5 power plant.

 

[topgun217]

Your Back ! I beleive we've been waiting to see what your next step would be on your return home. I remember when I was stationed at McDill, seeing their cucv's all running in their compound for 1/2 a day. Those trucks rarely moved. Hey, keep the pics posted, and again thanks for your service to our great country.

 

[SGT Estum]

That's a REALLY nice looking truck. You'll have a real solid machine by the time you get her done.

 

[ODdave]

while your right there and spending good coin on the truck change out that front diff lube with some quality synthetic lube. GM has a bulitin on this b/c of a high rate of failiers. Sweet truck!

 

[Recovry4x4]

While not the cheapest folks on the planet, RPM diesel down on 84 does top quality rebuilds. I got a bunch of miles out of my last unit from them.

 

[Stonepicker1]

Got the old engine out this afternoon, everything went well. I took the power steering bracket assy off the engine instead of of trying to remove the lines.

 

[Stonepicker1]

Here is the old engine next to the new one.

New HO water pump, Injectors and Glow plugs.

Now to find a new or rebuilt injector pump #5521S with the gray PMD

 

[Stonepicker1]

Worked on switching parts over to the new engine. I think I found out why the rod bearing melted.
The oil pump rod was broke off....see pictures. Not sure what broke the rod.

 

[WARWAG]

Very interesting find. I wonder if it was defective.

 

[FMJ]

Worked on switching parts over to the new engine. I think I found out why the rod bearing melted.
The oil pump rod was broke off....see pictures. Not sure what broke the rod.

Bet the oil pump went south. . .

 

[transman]

A good site to check for an IP and related electronics might be ssdieselsupply.com. all they deal with is 6.5s. I 've had good results the few times I've delt with them.