Dually M1028A2, South Florida Rebuild

[Stonepicker1]

It's time to get my M1028A2 Dually back on the road. The CUCV-II rebuild is still on going with little things here and there. overall it turned out well.
CUCV-II, South Florida Rebuild - Steel Soldiers::Military Vehicles Supersite

Now for the Dually. A little history first: about 5 months ago I made a trip to Redstone, AL to pick-up a 30kw generator. Then I headed onto SC to pick-up a new 6.5L GEP from Jackson, SC. About 15 miles from Jackson I dropped a valve and bent a rod(my son was driving and may of be pushing to high of RPMs). It was after midnight and I was broke down on I-20 so I got on Steel Soldiers and asked for help. FERRO showed up with an M818 to tow me to the nearest hotel.
The next day SCSG-G4 showed me SC and helped me get parts. After the next day FERRO towed me to MITCHG place were FERRO, MITCHG, BIGUGH20, JWALLER and SCSG-G4 helped me and my son swap out the dead 6.2 for the 6.5. Thanks again guys for the help.
After the swap I test drove the dually and it had a lot more power and seemed to be running fine at the time.

I headed out the next day around 4:00 pm and when it started to get dark I saw my lights were getting dim. I just made it to I-95 and stopped at a truck stop to see if I could fix the problem. A ground wire was off the #1 Gen that hooks to the top of the engine, because of this it wasn't charging.
The truck stop didn't have any batteries so if I turned it off I wouldn't be able to start it back up. I left it idle all night with me and my son in the cab(that was a long, cold night).
In the morning we headed south on I-95 and after about 40 miles found a Sams and bought two new red top batteries and got fuel. The truck was running so good I didn't want to switch out the battery just yet, so back on I-95 we go. After another 20 miles I turn to my son and say this 6.5 is sweet and has a lot of power. Not 30 sec later the engine started to knock. Long story short, the glow plug on the rear driver side came apart and went into the piston.
I used AAA to get me to Exit #2 in GA. and RECOVRY4X4 drove his Duce from West Palm Beach to towbar my dually and trailer back to his place.

Pictures of the old 6.2 and the new 6.5 GEP.

 

[Stonepicker1]

Some more pictures: Piston with glow plug chewed up on top.

Plans are to use parts from the CUCV-II 6.5 engine to fix this engine. Also adding a new Banks turbo system that I bought last year, a new water pump and maybe go with an electic fuel pump. I'll know more after I pull the engine.

 

[GM72K10]

Good luck with this endeavor.

 

[WARWAG]

another great build or ah... rebuild.

 

[NICK_M1009]

Nice, another rebuild. The CUCVII was awesome. I'll be watchin, I love that dually... Good luck.

 

[Fuzzy]

do you think its possible that the valve dropped due to the newer eng oils that are out? due to the new emissions/ lack of zinc in the oil?


my old shovel head dropped a valve after a 800 mile trip. I was in bfe and needed oil...the only thing the gas station had at the time was aviation oil on 70 wt. I used it and didn't think anything of it....about 1 month later and 1k miles I dropped a valve on the highway...I feel it was due to the oil...


I read your other rebuild..good job.

 

[Westech]

Yeah oils today suck compared to the engine oil 25 years ago.

 

[Cucvnut]

sweet build up man you really go in to detail and make them worth reading!

 

[cjtroutt]

An very nice find and sweet build we need more photos thank you.

 

[bigugh20]

Phil - that is one great looking 1028 that you have there. Hopefully, all goes well this time around.

 

[Stonepicker1]

Worked on pulling the 6.5 engine out of the Dually today. Took about 5 hours to do by myself. I'll open up the engine Sunday and see if there are any problems inside. Hope all I have to do is replace the bad piston.

 

[BKubu]

Phil, I love that truck. Keep me posted if you ever decide you want to part with it (or your green M1028A2).

 

[Stonepicker1]

Phil, I love that truck. Keep me posted if you ever decide you want to part with it (or your green M1028A2).

Will do, Bruce

 

[Stonepicker1]

Well, I couldn't wait until morning so I did a little work on the engine. Everything looks good except for the one piston with the chewed up glow plug.
The piston I removed from the CUCV-II's old engine looks like it will work(see pictures)

 

[Nonotagain]

The 6.5 piston skirt looks a little smaller than the 6.2 skirt.

Do you have a scale to weigh the pistons? Also check the rod for straightness while you have a chance.

I see wreckerman must have made the trip with you and his best friend "Murphy".

 

[ryan77]

If you have the pistons pulled take them to a machine shop and have the rods, pistons, reconditioned and get some arp bolts for $200.00 bucks its cheap insurance. I really enjoyed your cucv 2 thread and this one i like the info and pics!!!!!

 

[Recovry4x4]

Most certainly need to get that piston on a scale. Can't do anything without knowing the weight is correct. I would also check to see if you can find any casting numbers in the piston.

 

[Stonepicker1]

The numbers Inside each piston are the same:
10238517

339P
52

GM 83806 (the 8 could be a B)

Next set of pictures will show a differance on the outside of the piston(see black arrows)

 

[Stonepicker1]

One piston(good one) is out of the old 1999 CUCV-II 6.5l turbo-charged engine with 16,000 miles. The other(bad one) is out of a 2007 GEP 6.5l non-turbo engine with 150 miles.

I was trying to do this a cheap way by using parts onhand.

1. Could I just replace all the pistons in the GEP engine with the pistons out of the turbo engine and replace the rings with new ones. I would only change the piston not the connecting rod.

2. Buy just one, new piston for the GEP engine(where to get one thats matches the others ??)

3. Buy a complete set of new pistons(not what I want to do) $$$

 

[Nonotagain]

Complete sets available on one of the auction sites.

6.5L 395ci V8 Chevrolet GMC Hummer Diesel Piston Set - eBay (item 150578357094 end time Apr-16-11 06:38:20 PDT)

Before I went off to purchase a set of pistons, I'd weigh what I have and see if the weights are close, within +/_ 2 grams.

As for the piston weight, cleaning 2 grams of casting flash from the inside of a psiton is pretty easy.

If they are close, I'd purchase one set of rings and install them. Run a cylinder hone to remove the liner color, throughly clean the bore and install the piston.