12V Swap into 2003 Excursion - Dodge Cummins Diesel Forum
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post #1 of 105 (permalink) Old 07-16-2018, 09:42 AM Thread Starter
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12V Swap into 2003 Excursion

Start of my actual build thread. Planning on posting only the Cummins Swap here and the resto mod on FTE unless y'all want to see the other "resto" portion of this build.

Got the 12V torn down yesterday. Overall it went pretty well! This motor supposedly has 250K on it and you wouldnít know it based on the internals. All bearings look really good with just a little wear. Front of the crankshaft has the tiniest bit of wear. #5 piston had a little junk in it but other than that they all slid out easily by hand. The only real issue I had was the exhaust manifold bolts broke off, well most of them. And as an added bonus, my youngest learned that she really enjoys the crap out of using an impact! The harbor freight 2000 pond engine stand works fairly well except for the standoffís on the brackets arenít quite long enough to rotate the engine all the way around. This week, itíll go to the machine shop where a 75 year old guy will take his 60 or so years of experience to task checking EVERYTHING over. After everything has been checked, itíll get a valve job, check for cracks, hot tank, the works. Then itíll come home for paint and assembly. In the mean time, parts will be ordered, Iíll rebuild the turbo, clean up everything that didnít go into the tank, and send out the p-pump and injectors for evaluation. Went ahead and started cleaning up parts yesterday and ran into some issues getting the turbo off of the manifold and apart in general. Propane torch wasn't cutting it for heat, so I'll pick up another bottle of Mapp gas and se where I get to. Snapped off 3 bolts and called it quits. I'd rather not spend a bunch of time drilling and tapping if I don't have to. Itís on!!

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post #2 of 105 (permalink) Old 07-16-2018, 09:45 AM Thread Starter
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More pics. didn't realize I can only upload 5 at a time.
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post #3 of 105 (permalink) Old 07-16-2018, 09:46 AM Thread Starter
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And, for some reason they're turned the wrong direction...
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post #4 of 105 (permalink) Old 07-16-2018, 09:47 AM Thread Starter
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During the process, I thought I was taking a ton of pictures, but I feel like I didn't.
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post #5 of 105 (permalink) Old 07-16-2018, 09:48 AM Thread Starter
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P-Pump and turbo on the bench. Rusted bolt removal didn't go well at all.
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post #6 of 105 (permalink) Old 07-20-2018, 12:34 PM Thread Starter
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Dropped the 12V off at the machine shop today to have it gone through. The guy that's gonna go through it was a little concerned about #5, but once it's cleaned up and hot tanked he'll check it for cracks and make sure everything is up to speed. I have my fingers crossed.
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post #7 of 105 (permalink) Old 07-23-2018, 03:56 PM Thread Starter
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Spent some time with the bench grinder and parts cleaner this weekend. Cleaned up a bunch of bolts and some other parts. Also, checked my tappets for flatness. The camshaft, on initial check, is within spec. Several of the tappets are cupped in the center as I can see a bit of light with a straightedge across the top of them. What's the general consensus on replacing them? I looked around and didn't see a specification for flatness. Goal for the motor is longevity with little to no power modifications. Also have some significant pitting in Cylinder #5. Still haven't heard back from the machine shop, but there's only one thing that causes that to my knowledge. And only 3 ways it can happen.
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post #8 of 105 (permalink) Old 07-25-2018, 06:22 PM
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The head needs to go to the shop, that pitted valve needs replaced and the head checked for cracks.
I see some etching where the head gasket ring mated to the head, the head will need a light milling to flatten and remove that etching.

Post a photo of the tappets and of the cam lobes
The tappets should have a slight crown, being cupped they need to be replaced.
Check the cam lobes for wear and pitting especially near the top of the lobes, much of ether will require replacing the cam.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
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post #9 of 105 (permalink) Old 07-25-2018, 09:25 PM Thread Starter
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For sure, everything is at the shop now being checked thoroughly. He has the cam, but I have the tappets. Iíll post up a pictures....some are flat and some are cupped. The instructions to the guy at the shop were to quote everything itíll take to make it new again. He did do a quick measure of the cam while I was standing there and the lobes were within spec according to the manual I have. Hopefully heíll call with news by end of week, good or bad. Now that Iíve got this started, Iím REALLY chomping at the bit to get it done.
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post #10 of 105 (permalink) Old 08-01-2018, 09:45 PM Thread Starter
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Well, finally got around to taking pictures of the tappers. The more I look at them, the more I don’t like them. At any rate, here they are. Also cleaned up a few more parts. I looked quickly though the 12V powerteain forum and didn’t find the answer, so I’ll ask here. Is there a serviceability check for the oil cooler? I’ll check the manual I have as well. Looks like I’m in it for a turbo too as I cracked the compressor housing today trying to get it apart. Super irritating. I’ve never seen bolts this seized on anything. Ever.12V Swap into 2003 Excursion-35f1f4a2-230e-4fa8-8ffb-e9f90045563a_1533174253650.jpeg12V Swap into 2003 Excursion-413a49a1-89e1-44c7-b74d-3b827d59c7d3_1533174236006.jpeg12V Swap into 2003 Excursion-9149545d-4d0a-4500-8368-b5a17c20b278_1533174218952.jpg
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post #11 of 105 (permalink) Old 08-01-2018, 11:08 PM
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Tappets are shot, replace them.
There no real service limit for the oil cooler as long as it will clean up and flow good, but if there was any medal failure in the engine it should be replaced.
Medal particles will get caught in the coolers internal fins and could come loose later causing bearing damage or other issues.

Mine-04 F-450 SCFB 4X4 drw,5.9 12v 215 Ppump,ZF 6,KYclutch,KDP fixed,gauges,5x12's,15deg,3k GSK,60#,AFC Live, Super B single,Pusher intake,D celebrator brake,07 coil spring front conversion.
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post #12 of 105 (permalink) Old 08-02-2018, 09:29 AM Thread Starter
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There wasn't any metal on the drain plug in the oil pan when we pulled it to drain the oil. I'll see if I can flush it out and see what I get out of it. I really don't see any reason to skimp on parts that are even a little bit questionable. Seems silly to save a few hundred dollars now and spend more later.
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