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Old 12-10-2018, 09:54 AM   #1

Name: Hoiyay
Title: Green Behind the Ears
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Posts: 73
Piston to wall clearance?

Doing a fresh rebuild on my 5.9.

Had my machine shop do everything that needed to be done, even check rotating balance.

Anyways, I mic'd everything after I got it back.

My bores are all straight at 4.029" I saw in the service manual that the first rebore should be 4.034" and then honed to 4.036".

I thought that was odd, it's about 5-7 thou off. Was thinking my Piston clearance would be tight, so measured pistons too. They are 4.028" so, on paper I have about .00015" clearance. And in the real world (Piston in bore with feeler gauge) I have about 2.5-2.8 thou clearance.

What is the correct P2W clearance I need? I'm thinking around 6. I'm pretty damn sure the aluminum pistons will swell and seize with 2 thou.

The engine is being built to be a million miles work horse. Just aiming for durability (and possibly fuel economy). Thoughts? I think I need my machine shop to take out another 5 thou.
Old 12-10-2018, 09:55 AM   #2

Name: Hoiyay
Title: Green Behind the Ears
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PS. Posting here because this site seems more knowledge on engine building. The dodgecumminsforum doesn't seem to know much when it comes to engines. Asking questions like this I just get blank stares and crickets over there ha.
Old 12-10-2018, 10:32 AM   #3

Title: Too Much Time
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This thread has some of the info you are after.

Bodie @sanglesnail
2003 2500 4x4 auto 10.34 @ 128
2004 2500 4x4 auto QCSB Dually
2005 2500 4x4 auto
2008 3500 MAGAcab LB

Originally Posted by Snedge View Post
Anything stock is slow. That's why they invented money.
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