Consolidated Notes Thus Far
Please add or comment. This can be useful to many others I hope.
Forum links with some useful information:
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http://www.duramaxforum.com/forum/04-5-05-lly-duramax-powertrain/15910-head-gasket-replacement.html
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http://www.duramaxforum.com/forum/04-5-05-lly-duramax-powertrain/119592-head-gasket-replacement.html
• GM Specs
GM Specs - Duramax Diesels Forum need to have an account to view
• Photos:
Duramax LLY headgasket job - JohnVH's Photos
Notes:
• 50/50 to remove or leave the steering wheel shaft. If remove, move seat forward and tie seatbelt around steering wheel to keep from moving. Moving wheel could break a $500 plus clock spring. My friend who helped do a LB7 head gasket job did not remove the steering wheel shaft, but it was a tight fit.
• Check injector balance rates on Edge CTS before and after
• Should I take to a shop and pressure test or test the truck to verify if the issue is head gaskets or just do it because it will need to be done sooner or later? With all my symptoms which have been around for nearly 2 years, I better get on it and just change them.
• New exhaust manifolds? Drivers side is restrictive, is it beneficial to replace? I see LML driver’s side manifolds on e-bay for $150 free shipping. Passenger side good?
• Valve lash specs are .012 many are going to .010 quiets things down… probably end up around .011
• Driver’s side rear bolts are tight fit. Put them in the cylinder head and tape them to hold in place then put head on and install.
• Removing the motor for my head gasket job is NOT an option
• What is this comment someone wrote about? “Check the coolant crossover on the driver’s side above the oil filter. It's a 90 degree aluminum piece that connects the oil cooler to the adapter plate. It's a common failure area, and only about two hrs to repair”
• AC needs to be recharged? My buddy didn’t disconnect the AC lines on the LB7 and will try the same again.
• ARP Head Studs are a MUST.
• Machining specs on heads? What is the surface finish? Do the heads need to be decked?
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Here are some head gasket kits:
• Merchant Automotive in Michigan with exhaust manifold gaskets
Merchant Automotive :: Duramax and Allison Experts
• ATP Trucks in Idaho for all with exhaust manifold gaskets
www.atptrucks.com
• Diesel X in Nevada w/o exhaust manifold gaskets
http://dieselx.com
• Creatures of the Night Performance in Delaware
Creatures of the Night Performance
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Part numbers
• Genuine GM Head Gasket Install Kit Part# 98403365
• Genuine GM Left Head Gasket Part# 12637785 (C-Series)
• Genuine GM Right Head Gasket Part# 12637788 (C-Series)
Parts/supplies needed:
• OEM Head Gasket kit with grade c head gaskets
• Exhaust manifold gaskets
• ARP studs
• Wheel well liner clips
• Brake Parts Cleaner
• Isopropyl Alcohol 70% (for cleaning)
• Dex-Cool. How many ltrs?
• Oil at 155k should I be running synthetic? Pros vs. cons
• Oil Filter
• Fuel Filter what brand? CAT conversion worth it?
• Fuel line disconnect tool
• Flywheel lock for easier fan removal
Lisle 22100 Flywheel Locking Tool for 6.6L Duramax : Amazon.com : Automotive did w/o before, but harder… cheaper versions available?
• Turbo outlet? Brands? Prices from around $150-$250 and up. Benefits worth it?
• PB Blaster
• Shop towels, paper towels
• Masking tape
• Marker
• Plastic ziplock bags various sizes to store small parts
• Camera to document teardown for reference when reinstalling
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• Beer
Special Cleaning Requirements
For 2001-2006 vehicles produced with the first generation head gasket, special attention must be given to the cleaning of the engine
block and cylinder head surfaces when servicing with a second generation gasket. The crimped areas (1) on the first generation
gasket may, over time allow corrosion buildup where they contact the block and cylinder head surfaces. The second generation
gasket has raised ribs that seal at these crimped areas (1). A special cleaning procedure is required to ensure proper sealing.
Cleaning Procedure
1. Remove the old head gasket using service manual procedures. Save the gasket for reference until the repair is completed.
2. Place clean rags in the cylinder bores and pushrod openings in order to keep out debris.
3. Use the J-28410 or equivalent to carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping,
take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt
holes.
4. Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first
generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the
sealing surface is sufficiently clean and smooth, use the revised torque specification listed towards the end of this bulletin and
continue with published service manual procedures to complete the repair.
5. For surfaces that have corrosion or pitting, wrap a piece of flat steel (4" X 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, P/N 88862629 (in Canada, use 89020803) or equivalent, wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit.
Notice:
^Do not use any power type sanding devices.
^Do not use a wire brush or wheel to clean gasket surfaces.
^Do not use chemical cleaning agents on gasket surfaces.
Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion
will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface.
6. Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time,
to prevent sanding debris from building up and contaminating the oil and coolant cavities.
7. Clean the bolt threads and holes and remove the rags from the bore cavities and pushrod openings.
8. Repeat the above cleaning procedure on the cylinder head gasket surface.
9. Clean the engine block and cylinder head gasket surfaces with Brake Parts Cleaner, Isopropyl Alcohol 70% P/N 12378556 (in Canada, use 88901247) or equivalent, to remove any traces of oil or debris.
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