2006-7 LBZ Rebuild-Motor, Trans, and[emoji47]

[Sammconn]

Been a busy few days.
Unfortunately at work not the truck.
But still pushing forward.

Wednesday night I repulmbed the air bags.
That took Tuesday night getting parts from a buddy. Which took a few hours and a few beers.


Started by removing the original leaking fittings. The leaks are on me as I didn’t put any schmoo on them and said meh, this that is here is good. Knowing full well it likely wasn’t.


Tied and tucked it all away and now is a single fill.


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[Sammconn]

With that done and carpets cleaned by 6 I could put it together to move out.




This little gem from Amazon saves me every time I take something apart.

And with it all the weatherstrip and mouldings for the cab went back on.
Fenders and doors went on and out it went.


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[Sammconn]

Friday came and my buddy and boy came to move the bed into the tent and that shenanigans began.


Friday night was just a pressure wash to get all the loose stuff out.
Saturday morning the scrapers and hammers went to work. It was so humid I had to put the fan blowing at the bed to dry it out.

While it was drying I spent time stripping an old repair and paint around stone chips. Which there were many.



Also stared cleaning the seam sealer and debris out of the inside.

And by 2100 this was the result.


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[JR]

Came out good. Was it worth the work vs a used bed?

[Sammconn]

Came out good. Was it worth the work vs a used bed?

No.
It’s plain wore out.
It’s junk to be polite. Lol.

It will however make a few more trips around the sun now.

New bed is in the cards.
8 footer if I have my way…

[Bigdave_185]

I think you have made a fine dent in your list of todo’s on that ol girl!! Keep at it


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[Atkinsmatt]

When you finish that, about all that is left is new tires.  Great work.

[Sammconn]

Matt…I have more tires than I care to admit, and a new set for the 17” wheels is in my shed.
Good Year Duratrac 285-70-17. I believe they are right at 33”, hence the Nor-cal tuck.

But last night after the big update got the raptor shot.

Was supposed to be colour matched. We shall see tonight, but, it looks just gray to me not silver birch.



The cause for the pause…
Deer tenderloin and twice baked bacon and cheese spuds.



Let it start to cure some and unmasked at about 22:00.
At 06:00 today it is still soft but has started to set up. This is stuff I bought I about 2018 so I was a bit concerned. It is also a beautiful 53* this morning so curing will be slow.

Today I’m out with a wood stove inspector after lunch to check the casa stove install then onto paint.
All goes well by 21:00 it will be curing.


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[Atkinsmatt]

I have had a couple silver birch metalic vehicles.  Really like that color.  Both of those items pictured are a good excuse.

[Sammconn]

I love the silver birch.
It always looks fairly clean.

Now with extra clear I’m waiting to see. Lol.

So the non update update is it was too cold Monday to paint. I painted yesterday afternoon and it’s done. Well the box is done.
It ain’t show car quality but it’s a 300+ mile truck that is worked. When I shot the primer the slight waves shows up. I could have stopped and fixed it but there is no value in wasting more time or money on this box. It’s old, I want a new 8 foot version, and I was short on time and as it turned out short in primer.

Monday was spent putting the cab back together.
I added more sound deadening into the back corners and cleaned and reassembled the plastics.


Need to stick the flares on to hide this for the trip…




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[Sammconn]

Oh yeah. So I’m the middle of this paint job I need to address a couple things. 
One being an oil drip.
So into the oil pan I go.



The PPE pan doesn’t come with a new o ring and says to lubricate when installing…

Well 50k later I’ve got a terrible drip that’s getting worse. So timing was critical as I needed an oil change. Didn’t need this in the middle of paint but gotta do it while it makes sense.


You can see how wet it is in the outside where the connector plugs.

The old one was still in one piece when I picked it out, but immediately broke when I pulled to bring it off. So dried out and dead it was.

Surgically cleaned and ready to go back on.

Because I needed the sequence.

And back on. You can see the evidence in the muck of the leak. The rear main weeps every now and then but the oil level switch is 99% of the oil mess.


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[JR]

I think mine is "puter" just a darker silver.

Was it the o ring?

[Sammconn]

I think mine is "puter" just a darker silver.

Was it the o ring?

Yes the o-ring was failed/failing.

[Flyin6]

Into the motor now...I knew it

Most extensive rocker rail and cab corner repair in history!

[Sammconn]

Into the motor now...I knew it

Most extensive rocker rail and cab corner repair in history!

Surely you understand the need to be thorough.

[Bigdave_185]

Lol oh boy he’s got ya now!!! Read him the riot act now boss man!!!

New pistons and crank next


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[TexasRedNeck]

Sam you are getting so good at working on that Dmax, come to Texas this winter for a break from all that snow and ice and help me yank the motor on my LB7!


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[Sammconn]

I’d love to Charles. Just don’t know if it could be in the cards or not.
Truthfully getting tired of the bodywork stuff. So wrenching for a couple hours was a nice change.

But onto reassembly.

Inadvertently when I spun and dragged and flipped the box around I placed it tailgate away from the street. I suppose that was my ESPN working overtime for me.
It allowed me to back the truck up to the box in preparation for reconstitution of the pickup.


I phoned a friend and placed an order for a couple sets of hands for a few minutes. And once they showed up, voila, box on, a few bolts in to secure it relatively to add the topper.
From there I could shift and realign everything.
Being the bed has eight well placed holes it was easy. The topper is secured with 4 x 1/2” bolts now so it was also easy.
Got on a roll and stopped taking pics for a bit and finished adding all the hard parts.

Those front fenders are a harsh reminder of where I started and will soon be replaced with new.
Everthing back on the truck now.

For the record I have a bunch of extra parts currently. I kept stealing better stuff off the donor as I went, so with Amy luck they all belong there.
 
But done for this week as we’re heading south to sign papers for the retirement official casa.

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[Nate]

tell us about that samm

[Bigdave_185]

Lookin great!!!


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[Sammconn]

tell us about that samm

Well, we have but our one son.
He and his wife have been sending pictures and listings non stop.
There is an ‘area’ they (being the whole lot of the in-laws, outlaws and the rest) want to be at, and visit regularly.
Not on water, which I’m ok with.
No waterfront taxes and issues.
About a one minute walk to the marina.
So close.
Family own the place next door.well you get the picture.
Shop is 30 x 42 plumbed for in floor heat, 12” ceiling.
And there’s a pretty red house that 6 liked.

[Nate]

tell us about that samm

Well, we have but our one son.
He and his wife have been sending pictures and listings non stop.
There is an ‘area’ they (being the whole lot of the in-laws, outlaws and the rest) want to be at, and visit regularly.
Not on water, which I’m ok with.
No waterfront taxes and issues.
About a one minute walk to the marina.
So close.
Family own the place next door.well you get the picture.
Shop is 30 x 42 plumbed for in floor heat, 12” ceiling.
And there’s a pretty red house that 6 liked.

I pray it all works out for you and your family. I am sure you are going to miss your lake island place.

[Sammconn]

Thanks Nate.
I’m not retired yet. Just positioning things to be ready. I hope to be within the next 5 years.

As for the island cabin, until I’m physically unable to do it we’ll be keeping it. It’s almost zero effort already so there should be some good years after retirement out there.

My boat is good for here, and I’ll probably be looking at a pontoon for the south. Not sure just yet and time will tell. The boat may just get miles on land as well.


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[Flyin6]

Lol oh boy he’s got ya now!!! Read him the riot act now boss man!!!

New pistons and crank next


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You're right!
Thing is
He hooked himself
Easy fish... ;-)

[Flyin6]

Thanks Nate.
I’m not retired yet. Just positioning things to be ready. I hope to be within the next 5 years.

As for the island cabin, until I’m physically unable to do it we’ll be keeping it. It’s almost zero effort already so there should be some good years after retirement out there.

My boat is good for here, and I’ll probably be looking at a pontoon for the south. Not sure just yet and time will tell. The boat may just get miles on land as well.


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This is both surprising and wonderful!
I'll be keen to follow this as you transition to the next season of your active life (In a few years)

[Sammconn]

Ok
Oil pan holds oil again. That’s a win.
The stone chips have made my fender flare decision an easy one.
I need the protection.

Got a pretty new box of parts that will show up in the near futire.

We took possession of the retirement vllla and spent the week out there.
Was mid 90’s most of the week and I was totally fine with Netflix and AC.
I’d just spent the previous two weeks running ragged.

Tonight pulled the hood and sanded all the stone chips out.
Tomorrow should be back at the paint if temps are up enough.
Was 50 this morning…I’m not ready for fall yet.

With any luck my plan is to be down to doors by the weekend.

[Sammconn]

Between coats of clear right now.

I unboxed my new front fenders and broke out the angle grinder and welder.
Yeah not how one thinks new parts go.

But had to finish the Nor-cal tuck.

No other pics as it’s cut bend weld.
Oh and hope it still fits…

On to prep for paint.
This pic shows the about 3/4” I removed forward of the mount bolt hole.




Bottoms/insides primed.

Hood gets flipped as paint went on.
Jury is still out if I have enough to finish.
It’ll be some close.


Some clear on all sides now. Hood is propped up to get edges underneath.


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[Sammconn]

Ok so primer paint and clear.
All lots of the above.



They are all shiny and reflective and nice like now.
Tomorrow I’m back to lake to see the boss for supper. Probably stay and visit for the night.

Saturday I’ll be back into the thing.


Got to get to here… and back to reassembled.


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[JR]

Turbo too? Just got me a spare to rebuild, 250k and doing OK. Figure a good cleaning, good kit and a new billet wheel.

[TexasRedNeck]

Sam that just about qualifies as an oil change


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[Flyin6]

Sam that just about qualifies as an oil change


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Naw, Tex, trumpin' ya here
This is for sure an oil change.
Rust repair in the truck box seems to have migrated all over
Interior was out
Body torn down to a shell
New parts all over
We got into the engine
And doin' it again with a turbo...
Comprehensive rust repair does not cover it, so...Oil change it is!

[Sammconn]

Turbo too? Just got me a spare to rebuild, 250k and doing OK. Figure a good cleaning, good kit and a new billet wheel.

JR, I put a rebuild kit into my now failing nearly 350K turbo about 50k ago.
The motor never burned any oil prior, and has had the burnt oil aroma, as well as a quart every 3000 miles gone now.
I'm burning tons of oil, making 5 psi less boost, black smoke to the wazoo...etc.
All the signs of dead turbo.
As well, it sits DOA for a while (Depending on ambient up to a minute) before you hear the turbo spin up.
Sits zero boost while driving as well until it frees up.

So, stroke the cheque for a new OEM, not reman and I'll be good for another 300K.
Thats how I'm viewing it anyway.

[Flyin6]

Sam, you ever build a small home from start to finish in a single summer?
Learn to fly over a weekend?
Get a Ph.D. online over the Christmas vacation?
Get engaged/married/father children/ raise them and send them off to college in your spare time?
Solve Canada's political problems over lunch?
(One of the above is impossible)
;-)

[Sammconn]

Sam that just about qualifies as an oil change


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Naw, Tex, trumpin' ya here
This is for sure an oil change.
Rust repair in the truck box seems to have migrated all over
Interior was out
Body torn down to a shell
New parts all over
We got into the engine
And doin' it again with a turbo...
Comprehensive rust repair does not cover it, so...Oil change it is!

Yeah, ya guys got me there, I think.
The 'oil change' actually did occur...lol, but yeah, guilty...
 
And I'm probably not done yet...this is a forever truck for me, so updates and maintenance we need.

[Sammconn]

Sam, you ever build a small home from start to finish in a single summer?
Learn to fly over a weekend?
Get a Ph.D. online over the Christmas vacation?
Get engaged/married/father children/ raise them and send them off to college in your spare time?
Solve Canada's political problems over lunch?
(One of the above is impossible)
;-)

That one is impossible...
The rest....while some are unlikely...challenge accepted? Is that the right response...??? 

[TexasRedNeck]

Sam that just about qualifies as an oil change


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Naw, Tex, trumpin' ya here
This is for sure an oil change.
Rust repair in the truck box seems to have migrated all over
Interior was out
Body torn down to a shell
New parts all over
We got into the engine
And doin' it again with a turbo...
Comprehensive rust repair does not cover it, so...Oil change it is!

Didn’t he swap the motor out previous from a donor truck?


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[Flyin6]

I think so.

[Sammconn]

Yes donor provided the transplant.

Chief. How in the devil do you undo the turbo/up-pipe bolts?
Dang they’re redonculous.

Busted one bolt off in the passenger manifold.
Heated and thought it was turning. Nope.
At least it unbolted from the head.
Drilled, extracted and threads chased.

Now, I screwed up and didn’t order the gaskets for the coolant banjo bolts.
And ain’t no way I”mma gonna try to reuse.
Just too plain hard to get to if it leaks…
Decision time weather to put it all back together, we head south this week again.
Might take the Equinox, but it’s always soooooo tight on space.

[JR]

Sam, those bolts are a bare in a good climate. I think up there you add to that. I have not done mine yet, but read so many times how hard it is.

[Flyin6]

Concur...Up pipe bolts at the turbo inlet are the worse you will ever encounter, anywhere.
To defeat that system, I purchased a lower pedestal and bolted that in. Bolts easily accessible from above, then bolted the non-stock turbo down onto that fixture.

[Sammconn]

Chief, I’m staying stock with my turbo so I’ll be fighting it all back in.
Thankfully the actual applied torque isn’t significant. Getting the bolts out. Well those of us that know been there. I’ll get them.

So. Truck is back together again.
Not done and will need to come apart again.
I’m good with this.




When this pile of parts turned into the lack of all needed it gave me some much needed R&R.



This little gem, one of my 7 prime rib roast steaks became supper.


This, got reassembled.


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[Bigdave_185]

Fantastic progress! 


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[Sammconn]

So. Some more progress.
I’ve been fighting these dag gone bolts.


They are not fun.
Google said through the passenger wheel well.
Google was roght for four of them.

Took me and two buddies for one of the last two.
And two of us for the sixth.
Up pipe off.

Turbo bolts out.
Now searching for an E-torx to get the oil drain studs out of my way…


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[JR]

Didn't break any? great

[TexasRedNeck]

Really great


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[Sammconn]

Didn't break any? great

Not this round…
The first attempt when I didn’t have all the gaskets one broke in the exhaust manifold. It was a real treat.
These bolts are 14.8 grade I think. Drill like diamond…

Didn’t matter if any on the turbo broke as I had a brand new one to replace it. Frankly would have been easier if they did break. Lol.


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[Sammconn]

So…google said go through passenger wheel well.
Off came tire and all sorts of room for activities showed up.



With the room to crawl in created I reached in under and lo amd behold the bolts started coming out.
Four of them quite “easily” compared to the last two.
As I mentioned o had to recruit help. The last two yielded amd by about 22:30 a couple nights ago tje turbo was out.

That wasn’t without headache as well.
The three big bolts are tight. Unlike the mani bolts at 38 ft/lbs and take a small crane to loosen, these are at 80 and really need a good tug.

With all the main hardware out and lines disconnected the oil drain nuts was all that was left. Or so I thought.
With the driver up pipe still installed the drain won’t clear the studs the oil line mounts on. So out came the studs. But I don’t have any E-torx, and have been lucky up till now to get with a 12 point 5.5 mm(I think).
No go on far one. Found and borrowed a 7/32” spline socket. MONEY!
And out came the old turbo.





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[Sammconn]

With new vigor, I attacked this thing again last night.


Cleared the corner of my make shift work bench for the new turbo and began swapping lines over.

One by one old off new gasket and on it went.

Ready for installation.
A bit of a pain as well.

Now with no studs on place it was a small feat to align the turbo, oil return line, gasket, and bolt holes.

After probably the better part of an hour I recruited hands again. Even with six hands it was tough.
Just no way to see, other than two phones amd face time. So working blind by feel we got it in.

All bolted down and up pipe back installed.



It’s a long weekend for us this week and I’m going to try to spend it at the lake as I’ve not done that this summer much.
I recon about 4-5 hours to button up the engine bay and swap over to the new front fenders.

And for the p-nut gallery wondering…
The old turbo had at least 1/8” radial play on the turbine wheel. Had to be close to hitting the housing.  This likely cures all my ailments.

Oh, and that $;(& oil level switch is leaking again.
Time to order a Chevy o-ring…


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[JR]

I can see why people pull the cab.

[Sammconn]

I can see why people pull the cab.

The Chevy book says to remove the trans.
Not even kidding.

I’m not sure if pulling the motor wouldn’t have been easier. It would have taken a bit more time I think.

At least Thai is an LBZ…
It has hundreds more room than the newer ones.


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