FULL FEATURE - Bosch P7100 Rebuild for MINT 5.9L 1995 Dodge Ram x

Area Diesel Service Inc has partnered up again with @watchweswork for a rebuild for a rare beast - a mint condition 1995 Dodge 2500 4WD with the famous 5.9L Cummins 12-valve engine. This unicorn has been well-maintained and after Wes was able to do some repairs in his shop, an intermittent issue arose that pointed to an issue with the P7100 Bosch inline pump.
That is where ADS stepped in with our team of diesel experts, and 40-year inline pump expert, Gary Dahler, to investigate the issue and remanufacture the P7100 Bosch pump to better-than-ever status!
ADS experts guide us through the highly-detailed process, a process from start to finish normally takes up to twelve hours + to complete!
Follow along through this full-length meticulous process of assessment, disassembly, external clean up, blasting, internal parts cleanup, diagnosis, parts replacement, reassembly, Bosch test stand test and calibration, final touches and good-as-new review!
Watch Wes Visit our facility in 2021 - • Neglected Forklift Fin...
Any and all costs/pricing mentioned in this video are general assumptions regarding this specific project or projects very close in time, labor, and parts cost for this present time. All our work is priced case-by-case, and we offer quotes to assist in getting our customers the best and most accurate cost for the job.
We appreciate all the feedback and want to pass along that appreciation with a special offer for fans of this content. Do you have a pump or set of injectors in need of repair or rebuild and want to send it to our experts? Get in contact with us and mention our KZbin channel / Watch Wes Work for some ADS swag and we will cover the shipping - please reach out to us for more details.
To contact Area Diesel Service:
Call: 1-800-637-2658
Email: [e-mail]
Online: www.areadieselservice.com and utilize our CHAT NOW feature!
Socials:
Facebook @areadieselservice ( / areadieselservice )
Instagram @areadiesel ( / areadiesel )
LinkedIn @Area-Diesel-Service-Inc ( / area-diesel-service-inc )
Twitter @areadieselsvc ( / areadieselsvc )
Watch Area Diesel Service here - / areadieselservice
Watch Wes Work here - / watchweswork

[@garydahler8291]

Thanks everyone for their comments and inputs. I’d like to think every job I have done, is to this standard.

[@ShainAndrews]

Appreciate letting us look over your shoulder.

[@rpsmith]

It was awesome watching a true craftsman at work! Great job Gary!

[@tda2806]

Gary, you might feel that you have just "done your job", I would like to point out your skills, problem solving and methodical attention to detail are not "run of the mill" and you should be congratulated.

[@richardellis3141]

very nice work.

[@bostedtap8399]

Many thanks for being allowed to watch you work Sir. I got lost after 5 minutes, deft Hammer skills, and sublime hand to eye coordination. Certainly not a job for any sort of gifted amateur. Stay safe 🙏

[@dutchdb]

Came for the Wes connection, stayed for the content. Thank you for the effort it takes to post this, I enjoy the work!

[@johnfry9010]

That pump is a complicated beast , thank God for guy's like Gary who understand how they work and can fix them like new !

[@rayfoulkes5713]

I watched the deep dive. I love watching someone like Gary who totally masters their trade - whatever that trade is. It is often sadly missing from lots of organisations. It is for the same reason I watch Wes. He is really smart at diagnosing his problems but also knows his limitations and uses a specialist like Area Diesel when out of his range of skills. Thanks Gary for letting us look over your shoulder whilst you work.

[@elborrachogrande]

Gary is clutch. I love how he gets pissed that someone didn’t use factory parts.

[@deweydecimal1446]

That pump is insane. Wow, that's some serious engineering. It's far more complicated than the 12 valve it's typically mounted to.

[@deercreekmechanical]

Found about you guys from Wes’s channel. Sent you the CAV pump and injector out of my 1958 Lister LD1 over the summer, beyond pleased with the results. Can’t thank you guys enough.

[@chrisgallant9889]

Gary tells you how many years he has been working in this field. Just by looking at the work he does . Plus he explains a lot. You can literally see how many years he has without telling you. That is some awesome work you do. .

[@edhoran1709]

Preferred the "deep dive" version. Awesome job on that pump. Gary is one hell of a technician. He's a treasure for the company. Excellent video on what you folks are about.

[@Jimmyfisher121]

Geek level every time I loved watching a professional at work.

[@HUBBABUBBADOOPYDOOP]

Very much a pleasure to see a dedicated Craftsman at work. Especially nowadays- 40 years experience is hard to come by with anything.

[@LAKESIDEBOB1]

Long version was very educational, thank you

[@davidprattdo]

Excellent work, when I get an older Cummins to restore, I’ll be sending the pump to you for a rebuild. Thank you.

[@williamb2642]

Awesome technician..awesome video..tell everyone else in the shop to lay off the air tools when the master is at work!

[@paulhammond7489]

Probably the longest video I have watched on KZbin, and enjoyed every minute of it. Thanks guys.

[@josdaalmans6977]

I like both formats, The short one for quick info, the long one for detailed info. Nice job, proffesional done.

[@jonkinney1067]

You sir are a malfunction finding,investigating and answer getting guru, and a genius. Great job finding and investigating the problem. And an amazing explanation of the entire process

[@HogshooterHotrods]

Gary knows this work backwards and forwards, nice to see someone who has that "built better in America" attitude that was so common in years past! Great job thats for taking us along!!

[@Andrewausfa]

Amazing care taken. The pump looks like one of those WWI Mercedes in-line aero engines from the front.

[@tmscheum]

Came over from Wes’s channel. I don’t understand a lot of the technical talk but I do understand “shmoo”. Good stuff!

[@elmustachio3683]

That pump is ready for a million miles. Awesome work!

[@zrkn1]

American Quality Workmen = 100% QUALITY Guaranteed !!! Area Diesel Service must be so proud of its business practice and quality workmanship. Thanks to Wes for introducing A.D.S. to the entire country. Oh yeah, Gary you the man!!

[@KStewart-th4sk]

"Area Diesel Service" NOT "American Diesel".

[@JT-tz5hp]

I was surprised at how much of that classic diesel sound is from the pump. Always thought all that clacking was purely engine related.

[@robertasleson5856]

Great video. Learned a lot even though I am not diesel minded. Complicated piece of equipment. Gary knows his stuff. Great ending!!!

[@8osWeReTheBest]

These guys are the best!! They fixed my asv injection pump, and helped me with many questions. I will have these guys do ALL my diesel work! Thanks

[@lesmansom7817]

Excellent. Much better than the Cummins tutorial when I did my apprenticeship 😎👍🍺

[@dandydenni1615]

It is awesome to watch a true professional technician do their work. Thank you for bringing us along. I appreciate it. And thanks for slowing down to explain. I am humbled by your knowledge and skill. Long version - yea! $2000 actually sounds fair for a typical high quality rebuild/overhaul. Yes, $3600 sounds high and is, but me too as a customer would be pleased with no regrets. I came here from Watch Wes Work.

[@kevinwalker4623]

Gary is a BEAST and a legend! Red shirt dude, excellent use of schmoo, AVE would be proud!

[@henryD9363]

Damnation! That is complicated machine. It's probably more complicated than the engine itself especially in terms of the number of different parts and their interactions. Almost unbelievable

[@michaelclutton8446]

I have never watched a video of this length before on Utube, I found this long version fascinating, watching someone with Garys experience . I will certainly subscribe Mike UK

[@wacholder5690]

Who makes an over 2.5 hours video about an injection pump repair ? Other than you guys. And it was worth watching it all to the end. Thanks for sharing ! BTW: apparently these pumps base on those used on the fuel injection pumps used on the Daimler Benz 12 cylinder airplane engines used in WW2.

[@mdouglaswray]

Shout out to Area Diesel! I came here from Wes' channel, great to see this collab!

[@tomhurley3938]

What talent and skill! Almost makes me want to break something just to watch you fix it.

[@michaeltrinkle4197]

Stumbled on 2days ago an watched cc equip.rotary rebuild.easy to understand nothing but good i've heard over the years.detail understanding and listening to complaints and a clean environment.top mechanics who understand this complicated work.if only the younger generation and some do take jobs seriously.awsome video.Thanks

[@toma5153]

Like the split video format. Wish more channels did that - top level overview and then the nitty gritty. Great work.

[@NathanVogt]

Your expertise is beyond reproach. Great work.

[@bostedtap8399]

Pretty sure many petrol/gasoline engine guys are in amazement at what is involved in those old "Oil Burners", partly the reason these engines cost more. Excellent insight into the heart of a Rudolph Diesel engine. Love that bench swivel manipulater, par excellence all. Thanks for sharing, and many thanks to all . Best regards from the UK. John.

[@kevinmartin9432]

When I was an apprentice in the 70, part of my training was in the pump room, where we used to refurbish mainly CAV jerk pumps, I really enjoyed it, with a strip down area, and a separate clean room for assembly, then the calibration rig, Gary reminds me of the craftsmen that used to work there.

[@1lilfarm]

I like both versions. I watched the shorter version first and then this version to see some of the in depth stuff. Thanks!!! 👍👍👍

[@simonjones7785]

well done again to everyone at area diesel services great work

[@American_Creed]

Craftsman,craftsmanship and hard work is what makes America the greatest country.

[@tallyman15]

Great rebuild. A lot of labor for this. A master at work.

[@freedomfab319]

Watch Wes sent me here! If he says you're good you must be!!! Lol

[@zerajera]

Fantastic experience, dedication & skill. Really enjoyed watching Gary performing his craft on this pump. Thanks for sharing.

[@djosbun]

I’m not a diesel mechanic but if I am ever in need, you can guarantee that I’ll be doing business with your excellent team of professionals. Cheers from Cincinnati, Ohio.

[@patrickcolahan7499]

Excellent work Gary, your a true craftsman that pays close attention to the fine details. Something critical in diagnosing and identifying the source of the problem in this situation. A real asset to ADS. Thanks very much for sharing.

[@yomamaxx]

Dude's a magician...incredibly skilled

[@rhyde71800]

Gary you are a artist. came over from Wes’s channel Great video thanks guys.

[@curtisk84]

Very detailed and informative video. Thank you for taking the time to put this on here. Its very interesting to note the noise the pump makes during operation. The distinctive sound that the cummins engine makes when standing next to the engine I now realize is mostly attributed to the pump itself.

[@milantrcka121]

Bloody fascinating. Thanks for the autopsy and revival!

[@jltcasper3]

Garys a master of his craft great job would def send u guys my pump if needed

[@edwardkamenar1493]

Dude is amazingly good at those rebuilds. WOW, I'm amazed.

[@casycasy5199]

i will never use what i just watched for all most 3 hrs. but it was first rate .he explained every thing about the pump .i just couldn't stop watching.great video

[@Jameson4327]

One outstanding build

[@clarencewiles963]

That’s what it’s all about doing it correctly, and experience. Thanks.

[@edtoebes]

I bought my 24 valve pump rebuild from you. I also have a 12 valve with a P pump. If it has any issues when I get it restored, will be sending to you. Would have not known about you without Wes videos.

[@cesargallo7424]

These pumps are work of art themselves. The amount of pieces and devices to control fuel delivery is amazing! Gary makes it look so easy until we lift the hood and face the reality

[@wallss999999]

Gary is a awesome teacher. Very hard to find or keep someone like him. God bless

[@berniefudge4716]

Gary is amazing, totally amazing.

[@brendanhayes2752]

Love the long version.

[@carltauber2939]

Thank you for taking the time and effort to make this very interesting and informative video. It's a superb demonstration of the work of your company and its dedicated employees.

[@milwaukeeroadjim9253]

I came over from WWW to see what you guys do. I'm very impressed with your very clean shop and Gary's assembly and troubleshooting skills. I worked in manufacturing as an Industrial Engineer estimating and setting production costs on hydraulic product assembly and testing. Very impressed on quality of Bosch product for quality and ease of assembly.

[@garydahler8291]

Thanks Milwaukee. As much as I preach Bosch, we do use “after market” plungers in our Caps Kit replacement pumps. Outstanding. I’m sure they had someone like you involved. 😊

[@staind288]

Very interesting and informative! Thank you for sharing this process with us

[@douglasmayherjr.5733]

What an in depth video of the Bosch P7100 Rebuild. Your Technician Gary, knows that pump inside out, experience is hard to beat. Really appreciate the evaluation and cost of the repairs. When using OEM parts it is not cheap, but should last a lifetime. Thanks for the video. I am a fan of Wes’s Channel, excellent diagnosis and repairs.

[@jason86768]

Absolutely amazing video! I looked up your website and was tickled pink that you have a location in Indianapolis Indiana, just 1.5 hours away from me! If I ever need help with my 94 p-pump, I'll definitely hit you guys up!

[@stephenvale2624]

Amazing how many complex operations go into the building and calibration of something that on the surface sounds simple...like a fuel pump.

[@KStewart-th4sk]

"Fuel Pump", "Injection Pump" two completely different things.

[@malware_in_tn9008]

I’m not even a diesel guy and I enjoyed the longer version. Always interesting to get a behind the scenes with a rebuild expert. Makes me think twice before digging into a precision machine I know nothing about. Nice ending btw.

[@berniefudge4716]

My second comment is some people are good and some people are great and if you watch it all you'll know Gary impressed the hell out of me

[@jdsparky288]

Wow! Very detailed and put together very well! My only regret is the audio around the calibration stand wasn’t good. That was one of the most interesting parts to me, to see how the timing and fuel delivery was adjusted, but missed out on some of the explanation. Maybe a different audio/mic set up would help ??? Between C&C, Dirt Perfect, and now WES, I finally made it to your channel. I subscribed and look forward to future content! Growing up on my grandfathers farm I learned to work on equipment and trucks, and developed a fascination for mechanics. I still do all my own wrenching but I wouldn’t tear into a diesel pump for nuthin but trouble and a headache. It takes a skilled experienced expert to do “some” jobs and my hat’s off to Gary! I work daily with 480 volt electricity and trust me, you better know wtf your doing! Experienced skill is everything!

[@garydahler8291]

Thanks for your comments Sparky. I’ll do diesel, you do electricity

[@arthurfricchione8119]

New subscriber thanks to the recommendation of Watch Wes Work. You come highly recommended and I will enjoy watching your channel and videos starting with this one 🇺🇸👍

[@timkjos1495]

I watched the long version of this video. It was very informative. These diesel pumps are very complex. Any and all repairs should be undertaken by an experienced, knowledgeable mechanic. After viewing this I concur that it is money well spent to have the pump thoroughly inspected, and replace any suspect parts. You have a professional shop!

[@scoutman9452]

Really enjoyed watching an expert guide us through such an intricate rebuild process. Hats off to both of you!

[@robertwitkowski1650]

WWW suggested Viewers watch this channel. Wow! I'm not a diesel guy, had no idea how large and complex a pump was. Reminded a a little Kubota diesel. Great video. Thanks for the content.

[@jpop2499]

Another great video you guys have put together. I much prefer the long and extremely detailed version of any technical video. I don't care how many hours it might be, I will watch every detail with great interest. May I suggest a microphone for Gary to wear. I want to hear everything he has to say. Also multiple camera angles so we can see all the fine details. Suggestions for future videos would be checking and setting the governor foot engagement and governor teardown and rebuild for one of these P7100 governors, along with more details while setting the fuel rates on the calibration machine. Thanks so much for putting this together for us to watch and learn.

[@garydahler8291]

We have a similar video, on a P 3000 series Bosch. With the same governor. 4 part series. It was for a 8.3 forklift 🧐

[@tullydog9047]

Really enjoyed the video. Thanks for taking time to document and present it!

[@alwayshungry24]

love watching masters at work.came here from www,s channel. sat glued for the entire 3 hours so now i gotta go to bathroom lol.great vid

[@CHIBA280CRV]

What a beautiful craft , thanks for sharing 👍🏼👍🏼👍🏼👍🏼👍🏼

[@BrorAppelsin]

I enjoyed the video where Wes was visiting your location, liked and subscribed now!

[@ronzimmerman8968]

Great content! A lot of good information for us diesel owners. It was a pleasure watching Gary work.

[@nate4684]

This is the best video I've ever seen on the p pump. The knowledge you guys have is amazing I'll definitely be using you guys in the near future for pump work and other stuff.

[@simonjones7785]

my vote is the directorcut the full geek out deffo keep up the good work explanations are brilliant

[@rpsmith]

Excellent Job! I know where to get my pump repaired now!

[@Onerouss]

That is crazy, I'm shocked those o-rings can hold back enough pressure from the expanding grease to cause the barrel to compress!

[@davidmiller9485]

I just went back and checked, turns out i was right. That truck had a banks system on it. That isn't a fly by night company. The products they make are high end and very much on point. I've seen a banks power pack put over 100hp on diesel. He's quite picky about dyno tests (ie. They MUST follow SAE regs. or it isn't a valid test) and he's gotten some serious power out of his shop. So whoever worked on that pump was using high end parts, not that means that the installers (unless it was banks themselves) was any good. Just that those banks parts were tested to an inch of their lives and are very much high quality. Edit: i just realized that i never said who "he" is, that would be Gale Banks and it was just a cold air induction system that gave the 100 hp increase (actually it was 109 or so)

[@MiamiZombie2012]

Those pumps look cool, like a mini in line 6.

[@caveone-365]

Your company does excellent work! Love how throughly you guys do things and take care of the customer. This is the way it should be. Cummins P-Pump version is most definitely 'the one to have' if you're into good reliable performance that you can turn up easily and don't have all the emissions/ electronics B.S. Thank you very much for sharing this, I enjoyed it!👍👍🙂

[@redlinearroyo847]

Definetly subscribing after coming here from Wes. Great work.

[@tsitom3461]

Great job Gary! I prefer the full episode. If I ever need diesel parts or pump rebuild service I will call ADS.

[@huckelberryauditor5583]

Watch Wes Work sent me to watch this educational video. Thank you for maiking a long video for us special needs "want to be someday" mechanics

[@DAKOTANSHELBY]

Thank you for great video. The technician is a real professional. Question: Wouldn't your shop's test stand have been used to operate these pumps in advance to a teardown to not only attempt to duplicate the condition, but to measure pressures from each of the 6 outputs? Then after rebuild you retest and confirm to specs and show improvements? Thanks.

[@garydahler8291]

I don’t like adding time, and labor to a job. No matter how long it takes me to duplicate the situation, I would still have to rebuild the pump, to guarantee it 😮

[@nerdgarage]

I love both of these guys. It's friggin hard to find people who work at this level, ie in the guts in the back room, that are both willing and able to coherently explain the things they're working on in language that may not be ~quite~ layman, but that anyone who knows even the basics of the relevant field would understand. I do computers and electronics, not mechanics, and I was still able to easily follow every explanation and understand at least in priniciple what he was talking about.

[@garydahler8291]

I like your comment about working the back room. If someone else took it apart, I would miss many clues. I like to know every part and surface is cleaned to my standards. No back and forth.

[@williamlogan1775]

54:00 you can measure the spring height and tell. There's an visual difference between 3k/4k/5k springs...higher rates like 5k plus need additional work shimming/can be finicky. Great video. Love to see more of Gary. Pride in work for sure.

[@sirmister4411]

I commend you Gary great job I don’t have the patience to make a film like that it would throw off my system of rebuild. I have a system and order for tear down clean troubleshot and assembly and I hate to have to explain what I’m doing You did a great job and commentary

[@alanlashley943]

Very very good video! No back-patting, look what I did type stuff. Take pride in your work, nice job!

[@michaelshingleton1628]

Thanks when I worked at wv in the late 70's early 80's and rebuilt these pumps if the plunger was 1 and 1/2 degree hotter than the barrel the plunger would not fit in the barrel. So I can believe a little grease and oil could compress or more likely the barrel temperature would become cooler than the plunger due to the thermal conductive path formed by the grease.

[@carltonlane8931]

A brilliant rebuild,by a very skilled man, thanks

[@grudd61]

Awesome video! Gary is the guru for sure!

[@jamesrandalls6914]

i like the long version, thanks

[@garydahler8291]

I think I was on meds on the first version.

[@hawksights]

Great Video. You guys really know your stuff. It's great to watch experts work. But didn't you say you would level the top face of the pump too? I only wish, the sound was better. Like using a lav mic or so. As a non native speaker, I sometimes have a hard time understanding when the environment is noisy, but I could follow quite well. Oh, and of course I camer from www and the unicorn. ;)

[@AreaDieselService]

Thanks for the feedback, we are hoping to eventually upgrade the audio capture.

[@sarah-kenorum2852]

Nice to know that there are still Old school machine shops around that have the institutional knowledge to get it right. Why is there always time to do it again, hopefully there will not be a next time..