Bondo gets a little TLC, a heart warming thread. - Dodge Cummins Diesel Forum
98.5-02 Non-Powertrain Discussion of 98-02 Topics Not related to the Powertrain...NO ADVERTISING

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post #1 of 53 (permalink) Old 01-19-2019, 04:10 PM Thread Starter
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So im finally getting around to working on this project i got last year. I'll post updates as i go.

I got some 3rd wheels for it a few weeks back, only $200. Got rid of the 16.5" wheels it had.


The other day i took off the back up lights and put new wires on them. I just gotta figure out the rats nest of wiring behind the rear bumper and install them back in.


Last night i changed out the tappet cover gasket, no more oil leak now. I also did the valve lash.

The dash has some cracks and hole in it. So I spent a few hours this morning repairing the dash and i must say it looks pretty darn good, can hardly see the hole and cracks now.



The engine has a knock (I'll post a video of what it sounds like), so im about to drop the oil pan to see if i can find the issue.

Mine knock sounds just like this one.
https://youtu.be/AEQQ3CedhB8

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06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.

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post #2 of 53 (permalink) Old 01-20-2019, 09:21 PM Thread Starter
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This weekend i removed the stock fuel and lift pump since there is a fass on the pickup. I also cut the bracket that the lift pump bolts to. I cut the upper half off so if i need to remove the tappet cover again, that bracket won't be in the way. The lower part i put back on because a wiring harness bolts to it and it covers a hole in the block.

I started digging through this mess of electrical tape, chafed wires and crappy connections. Turns out it was only for trailer lights and brake controller.


The plastic pad on the driver side running board was held on with electrical tape. So i took the tape of and put some self tappers in there to hold it in place. The passenger side needed one screw.



When i got the pickup the cup holder was in the bed because it's broken. So i looked to see if i could fix it. One of the little arms had no resistance to hold a cup in place. I separated the cup holder and ended up wrapping electrical and a zip tie around this little arm to give it resistance. It worked out pretty good.





One of the hinges on the back of the cup holder was broken. So i drilled some holes, threw a zip tie around it and now it functions properly.





06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.

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post #3 of 53 (permalink) Old 01-25-2019, 02:26 PM Thread Starter
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Last night cracked the injector lines at the head one by one to see if my knock would go away. I skipped #2 and got the other 5 done. With #6 cracked the knocking went away. I was prepared to pull the engine, but luckily i don't have to now. This morning i ordered 6 new injectors and will get those installed in a week.
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06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.
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post #4 of 53 (permalink) Old 01-27-2019, 11:16 PM Thread Starter
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Got a few things done. The lid to the center console had tape over it, i assume it was torn. Went the junk yard and bought a center console with a good lid.
To swap the lids all you have to do is peel back some of the plastic trim on the bottom of the lid. Then you punch out the dowel out.





I took out the S&B intake and traded it for the stock intake tube and a BHAF.




I got the reverse lights on the rear bumper installed and wired up.



The pickup had no harness from the fog lights to the plug at the front crossmember. I replaced the factory plug at the crossmember with a 9005/9006. Replacing that plug was easier then trying to find correct plug. Then i made a harness from that plug to the fog lights.




The lenses of the fog lights were very hazy/yellow/cloudy to where you could barely see through them. I took them off and sanded them down. I just forgot to take a before picture.



The PO put HIDs in the halogen housings. I ripped that crap out and put halogens in until i do my retrofit.

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06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.

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post #5 of 53 (permalink) Old 02-04-2019, 03:53 PM Thread Starter
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I got the new stock injectors installed. Driving it around a little bit over the weekend i noticed the knock i had is still there. It is much better then it was before the new injectors. When i first start it up, the knock is still just as bad as it was before. The knock is only bad for a few seconds, then it gets better, still there but better.

Since i changed the oil pan gasket, i went ahead and changed the oil filter as well. I had one on the shelf for my 3rd gen, so i threw that on. I gotta order some more now.


My tailgate didn't have those bushing in the hinges, so i got a set from dorman and put them in. Now no more metal on metal clunking when i go over bumps.


I got a new 7 wrie trailer plug and 2' of 7 wire trailer wire. I found out what wires were for what function, put wire nuts on them and tested it on my trailer.

7 WIRE- OEM WIRES
^ ^
Brown- black w/red tracer
White- black x2
Blue- blue
Red- green w/red tracer
Green- black w/orange trace
Black- red w/orange tracer
Yellow- purple w/black tracer


I cut the OEM trailer wires back a ways due broken and chafed wires.


I connected all the wires together with butt connectors, soldered them and put heat shrink tube on them.


I wrapped it wire loom, electrical tape and secured it with zip ties.







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06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.

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post #6 of 53 (permalink) Old 02-04-2019, 04:03 PM
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Good work being done here. Also, good looking dog.

1984 Dodge CCSB P-pump NV4500- SOLD
2005 QCSB NV5600, SouthBend OKHD, CFM+, Jake brake, Thuren 3in, Steering brace, Synergy Track Bar, Vulcan w/ CAT UHE 416-1225, CTS2, HPTuners by Optimal Welding
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post #7 of 53 (permalink) Old 02-04-2019, 04:54 PM
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Looking good!


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post #8 of 53 (permalink) Old 02-04-2019, 05:13 PM Thread Starter
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Quote:
Originally Posted by Kmehr View Post
Good work being done here. Also, good looking dog.
Thanks. He's a purebred German Shepherd, i just haven't gotten him papered yet. I heard he was abused by his first owner and the second owner had him living in a 10x10 cage on concrete. Now he has 9.5 acres to run around on. I got him for free too.

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post #9 of 53 (permalink) Old 02-04-2019, 05:17 PM
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Quote:
Originally Posted by GRUNT 11B View Post
Thanks. He's a purebred German Shepherd, i just haven't gotten him papered yet. I heard he was abused by his first owner and the second owner had him living in a 10x10 cage on concrete. Now he has 9.5 acres to run around on. I got him for free too.

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Sounds like he's living the life now! My Dad always used to say "If reincarnation is a thing, I want to come back as a farm dog."

1984 Dodge CCSB P-pump NV4500- SOLD
2005 QCSB NV5600, SouthBend OKHD, CFM+, Jake brake, Thuren 3in, Steering brace, Synergy Track Bar, Vulcan w/ CAT UHE 416-1225, CTS2, HPTuners by Optimal Welding
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post #10 of 53 (permalink) Old 02-04-2019, 05:24 PM
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Love threads like these. Restoring a quality truck to its former glory
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2006 2500 4x4 Sport Package. CCSB. 6 speed. 256k.

All stock except different muffler.
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post #11 of 53 (permalink) Old 02-05-2019, 09:13 AM
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Professional level work on the wiring! You have almost identical front lights as my truck, did you have any luck getting them alinged properly? Mine are pointing too low and I kind of broke the upper screw trying to adjust the passenger side upwards.

I also may have to steal your idea about sanding the front fog light lenses

2001 Dodge Ram 2500 4x4 Cummins + NV4500/NP241
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post #12 of 53 (permalink) Old 02-05-2019, 11:24 AM Thread Starter
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Quote:
Originally Posted by Luoppis View Post
Professional level work on the wiring! You have almost identical front lights as my truck, did you have any luck getting them alinged properly? Mine are pointing too low and I kind of broke the upper screw trying to adjust the passenger side upwards.

I also may have to steal your idea about sanding the front fog light lenses <img src="https://www.cumminsforum.com/forum/images/smilies/smile.gif" border="0" alt="" title="Smile" class="inlineimg" />
Thanks. I haven't done any adjusting on the headlights yet. I haven't got the pickup registered or insured yet, but when i do, I'll look into my headlight adjustments. About a 1.5" drop at 25' is good.

I didn't fully do the fog lights properly. The correct way is stop sanding at 1000 grit and then spray clear coat on the lenses. Spray max 2k clear coat is the best rattle can clear coat to use. All the other brands like Rust-Oleum, Krylon etc. Are not a high enough quality clear coat.

06 QCLB 4X4 G56, SOUTHBEND DD, FASS 150, ARP STUDS, 50HP INJECTORS, EFI, HE351 S475 COMPOUNDS, FLUIDAMPR, HAMILTON PUSHRODS & 103# SPRINGS, 624 HP 1090 TQ 01 QCLB 4X4 AUTO, WHEELS, TIRES, STEERING WHEEL, CUMMINS, BUMPERS, FUEL TANK, SEATS, ETC.
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