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Author Topic: 84 Dodge One Ton Cummins crewcab conversion....  (Read 103489 times)

Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #75 on: August 09, 2010, 09:03:07 PM »

Well thought I'd update things....



I pulled the Injection pump after I couldn't get it to fire, and I had
spotted metal pieces in the pump when I had the top off to inspect other
 things...not good!!



So I pulled apart the pump the other day to inspect things.  Here's what I found.











That is supposed to be a hardened steel washer.  When I had the pump
apart to reseal things, I guess the washer dropped out of place and got
jammed up where it shouldn't have been.  The is a lot of spring pressure
 and torque through this area while generating the PSI required for the
diesel injection.  So one thing led to another and the washer shattered,
 it also cracked the head on the injection piston.



This is what it's supposed to look like, the washer that is.  And you can see where it supposed to sit inside the piston head.







So I'm going to talk to the local diesel injection shop here tomorrow
and find out what they figure it will cost to replace the broken pieces
and then rebuild the pump.  Turning into an expensive mistake...oh well
lessons learned, not cheaply, but learned none the less.

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Steve

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #76 on: August 10, 2010, 05:15:01 AM »

Yeah. . .But look at all the fun you'll have later.  Rust proof that truck and it will last forever
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Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #77 on: August 18, 2010, 01:13:44 PM »

Turns out the pump is toast, well parts are toast and not repairable or easily replaced.

The above pic of the washer adn piston head with keyway, well that piston head in mine cracked when the washer shattered.  I was cleanign and rebuilding everything when I noticed the hairline cracks.

The local shop quoted me $1400 for a reman unit, or about $1600-$1800 to rebuild and fix mine.  So I did some searching in craigslist and found a guy with one down in Tacoma WA.  He wanted $150 for a nice unit he pulled form another 89 motor, and mine is an 89 as well!!  So Monday night after the wife got home I drove the 3 hours one way to pick it up, and then another 3 hours home.  Well worth the travel.  I'm currently working on resealing this one and hope to have it in the hole by this weekend, and if karma is with me running not long after.


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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #78 on: August 18, 2010, 01:13:57 PM »

I worked a bit over the weekend on getting the frame built for my 2nd gen 40/20/40 seat.







With me being 6'8" and 275lbs I wanted the seat as low as possible and
set back to give me lots of leg room.  I have read almost every thread I
 could find here on the DTR related to this subject, and decided,
especially after I got my seat, that I wasn't going to use the factory
2nd gen seat tracks and brackets.



So I spent a fair amount of time trying to figure out what I wanted to
do.  Eventually I decide that I would do away with the dual tracks and
make a solid bench seat style set-up.  I also decided that I wanted to
use that factory bench seat tracks.



I then took all the measurements from the 2nd gen seat, pulled the stock
 bench out, but took tons of measurement, and then spent some time with a
 pen and paper drawing up several different ideas on how to attack the
situation.



I decide that I would build the frame out of 1" square tubing, 1/8th
wall, but wasn't sure exactly how things would work out in real life,
since ideas and drawing can't always predict everything.  So I came to
the decision that I would build the frame, initially, from wood since
it's cheap and easy to work with.  So out came the table saw, and some
2x2's I had around, and I ripped me a bunch of 1"x1" wood.  I then
started cutting and then used my finishing nailer to piece it all
together.



So after a few hours I think I have a final design, I had to modify it
several times from my original drawings and ideas, the tranny tunnel for
 the transfer case posed the biggest problem.



Here are some current pics of the project....















Now I just need to build it from steel.  Will update when I get it built and the new seat installed.

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Steve

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #79 on: August 18, 2010, 05:21:14 PM »

I believe Stan said Engine-uity. 
 

 
Lookin real good
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Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #80 on: August 18, 2010, 05:37:58 PM »


Quote from: POLARACO
I believe Stan said Engine-uity. 
 

 

Thanks Steve....

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Jason Goldsack

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #81 on: August 19, 2010, 01:38:03 AM »

Great Project.. I really miss my Gen 1 Cummins.. I put 250 000 km on mine over 10 years and it always started even in the dead of winter..

When the body was shot and the pump let go I sold it...




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Jason

(Eileen)1965 Chrysler Windsor, 361/727/2.76 16.49 @ 86 mph

Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #82 on: August 21, 2010, 06:27:29 PM »

Well ol' RAE is alive...again!!!!



After 2 months, and one bungled re-seal and a broken pump later, and
then a replacement pump and re-seal, ...I got ol' RAE running this
evening!!!

I resealed the replacement IP I got, installed it and hooked everything
 up and between 15-20 cranks, prime the injectors, then it quickly
rattled to life!!



I'll have to figure out the timing since when I installed the pump the
marks were way off.  Comparing the original mark to the replacement pump
  they were darn close, probably within 1/16th.  When I installed the
new  pump it was probably 1/4" or more below the original mark on the
case.   So I brought the pump up even with the mark on the case, to at
least  get it close.



I`m one happy camper tonight!!

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Steve

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #83 on: August 22, 2010, 04:53:34 AM »

Too advanced and it will be hard to start, but get great mileage and power.
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Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #84 on: August 22, 2010, 08:08:15 PM »


Quote from: POLARACO
Too advanced and it will be hard to start, but get great mileage and power.

What about not enough advance?  I think I have the pump set about 1/16th to a 1/8th less advance then the original pump.  Starts real easy though.

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Steve

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #85 on: August 23, 2010, 04:43:34 AM »

Yep. . .  It will probably be weak. 
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Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #86 on: August 24, 2010, 02:32:40 PM »

Well since I got old RAE up and running I've started to hear a tin type
rattle coming from the front of the motor.  I got on my old stethoscope
with metal tube on the end and started listening around the motor.  It
is most definitely coming from the timing case.




When I pulled the original IP to reseal it I decided to do my KDP as
well, so I had the timing cover off.  I didn't mess with anything else
inside the case other then the KDP and obviously the loose IP gear.  Now
 with the new IP I now have this major rattle.  I popped off the oil
filler tube to see if I could see if the snout on the IP was wobbling,
it's nice and tight.  But with the oil filler tube off it's a lot
noisier and I can distinctly hear it at 20-30 feet.





When I had the IP apart for the reseal I checked the front bushing, no
visible wear and the shaft was tight so I don't think this is my
problem.  I was thinking about it and I wonder if the key on the IP
shaft is partially hung up and the gear is not sitting all the way back
on the shaft like it should be? So then cause there to be an odd lash on
 the gear? Or what about timing?  If I don't have enough would that
cause the gears to rattle like that?  I have read here on the DTR about
running too much timing and the motor sounds like the old chevy 6.2/6.5
diesels, mine does not sound like that, it sounds great, other ten this
new tin type sound.





I just can't get a break....:(

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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

Steve

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #87 on: August 24, 2010, 09:14:49 PM »

I recall there was a pin yjay used to shear in those.  Had something to do with the timing gear.  I forget exactly what is was, but there are upgrade kits to repair it.  Maybe that's what you are hearing.  Could be ready to dump on you.
 
POLARACO2010-08-25 02:16:01
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Snotty

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #88 on: August 25, 2010, 09:19:41 AM »

Brian, my '87 360 4-speed RamCharger that I purchased new had the same sound from day one.  I never found it, but 79,000+ miles later when I sold it, the sound was still there and I never had a problem.  I chalked it up to the heat-riser, but never knew for sure.
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Brian

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84 Dodge One Ton Cummins crewcab conversion....
« Reply #89 on: August 27, 2010, 09:28:50 PM »

There was no noise like this before I swapped out the IP.  The guys over on the DTR diesel site I frequent think the timing gear  has got hung up on the woodruff key on the IP shaft.  I'm leaning towards that as well, since this would throw off the gear mesh and allow a lot more slop in the gears. 

I got the fan and shroud and stuff torn off before I went out of town for work, just got home, but will pull the timing cover tomorrow and check things out.


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Brian

02 Chrysler Concorde Lxi
84 Dodge Crewcab, Cummins/5speed
68 Chrysler Station Wagon 440/auto
48 Desoto 2dr Sedan flat 6/3spd manual

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