First time rebuilding

[WtfAmIDoing]

Ok so this is my first time rebuilding an engine and to add to the difficultly I need to do it reasonably quickly and cheap. Good news. Stock power is all I need.

The 03 I have punched the number 6 rod thru the block taking out the starter. I've got a 02 short block with rotating assembly to replace the block.

I'm noticing a few differences though and want to be sure this will work. The 02 block has a tappet cover but the 03 does not and has a coolant line in the spot.
The pistons are different but is the rest of rotating assembly the same.

Google seems of no use so I'll do a rebuild thread, with pictures, in case anyone wants. And I'll start posting pictures when I figure out how. Got something about a security token when I tried

[zachu812]

Some of the bolts for the timing case on the 03 won't fit on the 02 short block. There's enough to line it up then you can drill the rest, you're also going to have to swap crankshafts or at least the crank gear. I'm sure it's doable but it'll be a lot of screwing around, you'd be better off finding an 03+ short block imo.

[Snedge]

No. You don't want to use that block. Find a common rail block 03-07.5

[WtfAmIDoing]

Originally Posted by Snedge

No. You don't want to use that block. Find a common rail block 03-07.5

Thought 04.5 + was different?

Why do you not recommend the 02 block?

[WtfAmIDoing]

Originally Posted by zachu812

Some of the bolts for the timing case on the 03 won't fit on the 02 short block. There's enough to line it up then you can drill the rest, you're also going to have to swap crankshafts or at least the crank gear. I'm sure it's doable but it'll be a lot of screwing around, you'd be better off finding an 03+ short block imo.

Thanks. Got the 02 for 200 so if its doable I'm going to have to run with it. There's lack of a coolant line where the tappet cover is and the 03 didn't have a tappet cover so those had me scratching my head

[4x4dually]

I love the username. Fitting after reading " 02 block in an 03".

[Mark Nixon]

Get in touch with Mumau Diesel, for ALL of your diesel needs!

Mark.

[4x4dually]

Originally Posted by Snedge

No. You don't want to use that block. Find a common rail block 03-07.5

Originally Posted by Mark Nixon

Get in touch with Mumau Diesel ^^^^^, for ALL of your diesel needs!

Sounds like he will proceed with the '02 block and need lots of "adapter kits."

Jeff, you got glow plug A-dapter kits to convert and '02 block to common rail?

[RonA]

Originally Posted by WtfAmIDoing

Thanks. Got the 02 for 200 so if its doable I'm going to have to run with it. There's lack of a coolant line where the tappet cover is and the 03 didn't have a tappet cover so those had me scratching my head

I see you are new here and looking for advice. Not to seem rude, but the guy that posted above as Snedge is about as knowledgeable as you are going to find anywhere. If he doesn't recommend it, might want to re-think. He said that to be helpful, not to try and sell you something.

[4x4dually]

Originally Posted by WtfAmIDoing

I need to do it reasonably quickly and cheap.

Don't take us wrong, there new guy, but your statement above kinds says it all. Can it be done? Absolutely. Reasonably quick and cheap....no. Everyone here is just trying to help.

[WtfAmIDoing]

Y'all are good. I have to explain to the person rebuilding the motor why it won't work (I'm really the parts Fletcher trying to learn) and it would be easier if I could be more technical in explaining it to them.

Glad everyone paid attention to the username

[Snedge]

If this needs explained to the guy building the engine, you might want to rethink your whole process.
You would be further ahead to replace the entire truck. That's quick, and way cheaper than building the hybrid engine.
At the very least go find a used 03-04, use your ECM and wire harnes and run that. I'm not saying it's impossible, but I am saying it's impractical.

Just to name a few obvious road blocks you'll encounter
- Oil cooler and filter housing from 03 wont fit 02
- Gear drives are different. Helical Vs. straight cut.
- Gear housing bolt pattern is different
- your 03 oil pan won't fit the 02 block
- the oil pickup tube from 02 sump to 03 oil pump is different

I could list a more, but.. I say punt the 02 short block, eat the 200.00 dollars and do it right.

[4x4dually]

Originally Posted by Snedge

If this needs explained to the guy building the engine, you might want to rethink your whole process.

Confucius very wise man.

[displacedtexan]

I agree with Muamu and Jory Exotic.

This is something that a parts fetcher should not have to explain to the engine builder.

[kleann]

There's only 1 year difference how bad could it be?!?

[Snedge]

Originally Posted by kleann

There's only 1 year difference how bad could it be?!?

That's true. I guess before posting my thoughts, I should have verified build dates..... hell, they could be only months apart...

I do wonder how the conversation went with the "Builder"

[WtfAmIDoing]

Originally Posted by Snedge

That's true. I guess before posting my thoughts, I should have verified build dates..... hell, they could be only months apart...

I do wonder how the conversation went with the "Builder"

Haven't forgot about y'all.
Bought an 06 block to use instead. Current hang up is none of the cranks can b polished and I'm trying to find a company to turn it around the Baltimore Harrisburg area.

[Snedge]

UCF Machine shop Carlisle, Pa.

I do have a good used standard crankshaft here for 400.00. I'm in Western Pa. near Pittsburgh.

[WtfAmIDoing]

I'm suppose to be near Pittsburgh July 4th if I haven't got this figured out by then I'll be in touch.

As of now i stand here:

I've been on the phone today with cummins (sends theirs to rutts), Alban cat (checking with a different shop and will call me back), rutts of york (supposed to be emailing me prices) , frasers of Harrisburg (waiting for their new machine to come in July) , and 4 others yesterday (one on the eastern shore and jb's of rosedale said to call m+o by d.c... waiting for a call back).

Rutts seems to b the only place that will still acid dip blocks.

Of 3 cranks the best one needs to be turned and I'm told 10x10 should do it.

To satisfy my mind. Do I need to worry about strength with turning? I'm told cummins didn't surface harden theirs and the strength comes from the bevel.

Thankful for all the information I've gained from this site so far

[jasonc]

400 bucks for a standard crank in good shape seems a nobrainer over having a crank machined.