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Thread: P400 Turbo Diesel 4x4 Dually

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  1. #1
    Join Date
    Feb 2008
    Location
    N.Delta, BC, Canada
    Posts
    182

    Default P400 Turbo Diesel 4x4 Dually

    I may or may not be your typical guy, who was looking for a good economical diesel truck to do some light towing and summer camping with.

    I am 45 years old and have had my share of vehicles. I felt I had a reasonable amount of knowledge regarding the pro's/cons of Chev/Dodge/Ford... so I shopped the market for 3-4 months before making a decision.

    I bought my first Chevy diesel truck late last year. It was a 1993 extended cab 6.5 TD 4x4 Dually. I bought it with known oil pressure issues...


    She drove nice but needed another motor... I figured I would do some homework...ordered the TD Volumes I and II, and started reading.

    The motor was pulled and ended up being cracked in 6 places, so I bought a budget 599 rebuild for $2,200 off craigslist. It arrived with a chunk missing out of the block around the starter bolts... I claimed warranty and got my money back.


    Here is where I started my journey... I bought a "crack-free" block, certified by a machine shop near Dallas TX. Hot tanked, honed, and frost plugs installed... for $250. I paid $250 to get it to Washington State... it arrived and had 3 stress cracks in the main webs. I got $250 back but was out the freight.


    I bought 2 more blocks... they both had cracks !!! I lost money on one of them.


    The last block I purchased was OK's by my mechanic's machine shop and I committed a large sum of cash to build it. After the boring, decking, align-honing with a stud girdle, etc... I inspect it prior to assembly and saw a fatal crack in the second web!!! $1000 in machining instantly disappears into thin air... I had another $3000 committed to this in parts (rebuilding the heads, pistons, regrinding cam, crank, rods, etc...) Ouch!!

    My mechanic buddy is having this block repaired using inserts which are machined into the fractures of the block. I'll share photos after it has been done. Apparently they have been repairing cracked blocks for years... without issues. If it works, I have 2 more to fix.



    Long story short... I was ready to buy a brand new long block directly from Franklin Ohio for the tune of $6,090. I did this through a gentleman by the name of Rod Townsend and a company called WW Williams. Kennedy and Peninsular also offer this long block.

    The powerplant is the redesigned 6.5 Optimizer and carries the casting number P400. It was installed after I engineered an oil pan to fit my rig. This engine was designed for Hummers which now carry payloads up to 15,000 lbs. It includes a forged crank and cast iron girdle for added strength.


    In conclusion... I have spent a small fortune seeing this project through to completion... I do have a great truck, for 1/4 of what a new one costs.
    Oh... and my wife still loves me

    Last edited by JetBoater; 05-10-2008 at 09:31. Reason: typo

  2. #2
    Join Date
    Jan 2001
    Location
    Knoxville,Tennessee
    Posts
    2,639

    Default

    Nice truck! And a very nice presentation of your project. Enjoy your toy.
    "The Constitution is not an instrument for the government to restrain the people, it is an instrument for the people to restrain the government."
    -Patrick Henry


    A5150nut
    2006 K3500 D/A
    94 6.5 4x4 5spd Sold

  3. #3
    Join Date
    May 2008
    Location
    Odessa, Tx
    Posts
    10

    Default

    nice truck
    99 gmc 3500hd

  4. #4
    Join Date
    Apr 2001
    Location
    Newberg Oregon
    Posts
    12,282

    Default

    So sorry you had to go through such a tortureous path to get a usable engine for your rig.

    So many folks including good mechanics can be fooled by the 6.5 into thinking its crack free.

    Many shops simply dont know where to look and or how to easily find the cracks.

    Buying a 6.5 off the internet is a very sketchy proposition at best and unless the seller knows a lot about them he/she can be selling a door stop and not realize it.

    As you have found out some folks are honest and some are not.

    The freight is always a killer though on stuff that heavy.

    A few years back I bought two 6.2 blocks off ebay and had them shipped.
    Both were crack free and in very good condition. (Lucky)

    Glad you got your ride all squared away and going.

    I love the mid 90's body style trucks.

    I own a 95 Dually crewcab with the 6.5 TD

    Have fun and enjoy the beast

    Best

    Robyn
    (1) 1995 Suburban 2500 4x4
    (1) 1997 Astro
    (1) 2005 Suburban (Papa Smurf)
    THIS IS BOW TIE COUNTRY

  5. #5
    Join Date
    Jun 2006
    Location
    Surrey, BC
    Posts
    282

    Default

    I had my truck in the same shop as your truck a couple months ago and JR told me of your woes. I was going to stop in and see the new engine but I forgot all about it. Hope all is well now. I'll keep my eye out for you locally. I live in Surrey and work in N Delta. Happy trucking.
    Brett
    2005 GMC Sierra SLT Dually Crew, 4x4, stock
    71,000 kms

  6. #6
    Join Date
    Feb 2008
    Location
    N.Delta, BC, Canada
    Posts
    182

    Default

    a5150nut, rodburner, thanks for the comments.

    Robyn... the knowledge and experience you bring to the diesel page is a wonderful thing! Your comments on a previous thread about the oil pan fabrication were appreciated! I saw your latest truck... its a sweet ride. i think of these trucks as Old School with attitude!

    I am new to diesels, but have wrenched since I could pick them up. After studying the issue of cracks.. I believe the older 6.5's run fine with them. At least all my motors ran fine.. but died of other causes.

    I was going to write a blurb on the whole business of buying a long block off the internet. I came across some very shady companies.. who claim NEW blocks, but charge for the core. I thought I would need a lawyers advise before pen'ing the names onto paper. People should be aware of companies selling Chinese blocks with names similar to optimizer... and other scammers ready to sell you something supposedly dyno-tested for 1 hour, when they probably don't even have a dyno. I could ramble on for an hour about this... it bugs me. I am very happy to have purchased the strongest 6.5 currently offered.

    Brett, I saw your rig in the shop too... I hope its rolling better with the new rear end, brakes, and bushing kits. PM me if you ever want to chat.

    Cheers to driving a diesel!

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