How To Rebuild A 5.9 Cummins 12v Diesel In A Million Mile Dodge

Full rebuild / refresh of a 5.9 Cummins 12v 6BT diesel engine
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We show you everything you need to know to keep a million mile Dodge RAM hauler on the road by rebuilding a "new" 250k mile 5.9 Cummins 12v 6BT.
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Check Protrusion: www.liberatedmanuals.com/TM-5-...
Cummins 6BT Rebuild Kit: bit.ly/rebuildkit
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NO WARRANTIES: All of the information provided in this video is provided "AS-IS" and with NO WARRANTIES. No express or implied warranties of any type, including for example implied warranties of merchantability or fitness for a particular purpose, are made with respect to the information, or any use of the information, in this video. DEBOSS GARAGE ("DG") makes no representations and extends no warranties of any type as to the accuracy or completeness of any information or content of this video.
DISCLAIMER OF LIABILITY: DG specifically DISCLAIMS LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES and assumes no responsibility or liability for any loss or damage suffered by any person as a result of the use or misuse of any of the information or content in this video. DG recommends safe practices when working with power tools, automotive lifts, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video. DG assumes or undertakes NO LIABILITY for any loss or damage suffered as a result of the use, misuse or reliance on the information and content of this video.
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[@DEBOSSGARAGE]

Cummins 6BT Rebuild Kit bit.ly/rebuildkit Maximum Bolt & Nut Extractor Set bit.ly/extractorset Coolant Thermostat bit.ly/coolantthermo The above are affiliate links. Check Protrusion: www.liberatedmanuals.com/TM-5-3810-307-24-2-2.pdf

[@machscga6238]

DEBOSS GARAGE make sure you cover custom fuel economy builds and what transmissions can be used in engine swaps... Can you still use Chevy pre-Duramax/Allison transmissions from the old 6.5L Detroit for a 5.9? And vise-versa?

[@machscga6238]

DEBOSS GARAGE is that oil pan painted on the inside?

[@theshadetreewelder3523]

Is Engine oil good and is the same weight as what will be put in the engine during routine maintenance

[@13coyote13]

Crows foot on torque wrench.

[@jkuri89]

DEBOSS. quick question. Doing a bearing roll on my 6bt. Many say to buy new crank and rod bolts. Spoke with two Cummins techs and they say its ok to reuse them. Only thing for power adder is my home made AFC in cab control. Thank you.

[@MisterShredder]

These types of videos are replacing the old Chilton manuals. We are officially in the future. :)

[@chrisj197438]

Chiltons was never realistic anyway

[@viktor7495]

I have rebuilt a few with the Chilton manuals and videos are much more helpful

[@toomanyhobbies2011]

Chilton's manuals were good guidelines and included specs for experienced mechanics. They were in no way textbooks. Deboss videos are more like tech school training sessions.

[@samueltischler5462]

Yo i opened comments to like this comment and to my delight i already liked it last time i watched this video, lol.

[@mydogworriesalot1840]

@@toomanyhobbies2011 Good way to look at it I always thought well of Chiltons.

[@GuiltyPleasures]

I have a 5.9 24v in an 06 3500. Driving home to GA from NC, it developed a knock (noticeable at interstate speed). Immediately pulled over and had it towed to the nearest Walmart. After looking at what I could (it was around midnight, so very dark), I decided that I would just get it to the nearest Dodge Dealership (1/4 mile away), drive home, call them in the morning and have them diagnose / fix it. By the time I drove the truck out of the parking lot, it started thrashing (badly) and died. It would crank, but would thrash the motor / cab badly, so I turned it off and had it towed that 1/4 mile to the dealership. Tech cranked it, turned it off, said the bottom end was out and wanted to charge me $10,000 to $15,000 to put a "new" (rebuilt) Jasper engine into it. I believe - firmly - that an injector failed, chewed a valve seat, and it is - in fact - the top end that is out. I'll know shortly because .... I struggled for a week on what to do. After googling and watching videos (specifically, this one), I decided to tow it home and pull / rebuild it myself. Shop crane arrived 2 weeks ago and the engine stand came in last week. While I haven't had time to get it out just yet, this video series has given me the confidence to attempt the work. I intend to reference the *&^% out of this series (along with other, similar videos). Thank you. Thank you, so much. I intend to video the work and upload to KZbin during the process. I just wanted you to know how much I appreciate your videos. I am not a mechanic, I learn as I go, and people like you make all the difference.

[@razor3003]

Just wondering...how many miles on the truck?

[@GuiltyPleasures]

​@@razor3003 Around 180k. I have the engine out and on a stand. Piston #1 and #3 look ... not like new. The other 4 look good. Metal shavings on piston #1 and #3. Lots of metal shavings in the oil pan. Thing it chewed up a bearing. Trying to get to that today, only got it flipped over and the pan off yesterday. Ran outta time =P

[@razor3003]

Thanks. I guess that's unusual for a Cummins.

[@GuiltyPleasures]

@@razor3003 Well, I bought it used. No idea how it was taken care of. And, to be perfectly honest, I could have done a better job myself. Lesson learned. The silver lining is that, without that having happened, I don't know that I ever would have jumped into a project like this. Learning a lot, so ... something positive will come out of it. Also, DebossGarage gained a sub :)

[@GuiltyPleasures]

@@razor3003 Now that I have it completely apart, I found the problem and the cause. The oil pan gasket had completely blown out in a couple of places. It had not been burning oil before the trip, so ... I assume this happened at some point during the 8 hour drive there or on the way back before it broke down. Lack of oil... The rod bearing on rod #1 has eroded considerable (the cause of the metal in the oil pan) and has fused to the rod. The rod is simple enough to replace, but there's quite a bit of damage to the crank shaft where that bearing was at. I'm not sure it can be machined or not.

[@snowmobile488]

Thanks for a stock engine rebuild. I’m tired of all these high horsepower rebuilds.

[@2nsane2005]

Most informative 12 valve rebuild video on KZbin! Really enjoyed watching it. Learned a lot! Thanks heaps

[@dylanchapman3897]

I don’t know why but I have no need to know how to rebuild a Cummings right now but I just love watch Deboss videos

[@rkn3045]

This repository of information will allow 12 valves engines to outlast the pyramids

[@chuckfarley1655]

Bro that was coolest line ever

[@mikemiranda1154]

Your the first mechanic I have seen that videos the cleaning of surfaces on the bolt threads before applying locktite. Good job

[@rohantait205]

I love this dude. Keeping it old school af 🤙🏼

[@ScruffyMcRuffNutts]

I rarely watch 30+min videos but this one wasn't long enough lol. Great job on editing and very fun and informative! Im a huge fan of Cummins! some day ill build one myself so getting the small what to do's and what not to do's is really nice! Most channels will just show a before and after of what performance parts they got without the nitty gritty parts. Again Thanks for being a Bad Ass Channel!

[@timmayer8723]

You are the only video mechanic that has made a point of including the torque readings even for minor attachment bolts. I was trained as an aircraft mechanic and torque was the holy grail of engine assembly and all the control surfaces. Very professional presentation.

[@Racerboy535]

Rich reminds me of the old timer that taught me how to wrench. No frills, no wasting money and great information that is conveyed the best I’ve seen. Rich thank you for taking the time and forgive me for buying a 2019 eco diesel last week. If it’s any consolation I am keeping the 7.3 PS but the 2nd gens are getting expensive or are hammered here in Cali.

[@MisterShredder]

wow, make me want to give this a try! Thanks for taking the time to do this, this will help so many people!

[@frankyawbanini9625]

Please I will love to come to you to learn more from you so please help me

[@robertweaver3887]

Great vid! I’m new to Diesel engines and this vid really answered a bunch of questions I had. Good work young man. This vid will be saved and watched over and over again. I will be watching your other vids as well.

[@johnv1038]

Man 6bt is waaaay more simple than a dmax, I can see why so many people fall in love with these things. Great video!

[@jasonneels3760]

Not worth it. It's a $4000 truck scrap it and buy another one that runs.

[@Gonecheenin]

@@jasonneels3760 ^ 🤣

[@amorag59]

​@@jasonneels3760 This whole channel is about preserving machinery from being scrapped as long as it doesn't show signs of irreparable damage - not throwing equipment away just because it's easier to buy yourself a solution.

[@mmoser9483]

From what I know the B series were made for over 40 years.

[@clamdiggerdan8581]

Never worked on a diesel but I love every vid you make on the builds.You do a fantastic job walking us through each phase.Cant thank you enough.

[@trevorseals6588]

One of the most detailed quality videos on engine rebuilding, reminds me of my college engine class

[@HAIL4sure]

There are like a thousand of rebuild video's out there but what I like about this one is the "to-the-point" naration and focusing & highlighting on all the really important points without bulshit. Well done!

[@silassmith354]

This guy is probably one of the best mechanics in Canada. This channel is one of the best on youtube. Highly recommended.

[@almedin7212]

Dude really cool watching you work, you obviesly know what your doing. Love you videos man keep it up.

[@GETLOWDUDE]

I first started watching without even realizing it was 30 mins long, then all of the sudden it’s over and I just watched a entire 30 minute video without clicking off lol

[@douglaslambert6109]

Lol me too!

[@mattshaw4958]

I love watching your videos Rich. Informational and funny. Keep up the great work!

[@floridaracingchannel6245]

I love how you do everything by hand and dont use a impact like alot of other KZbinrs i see doing now. Its crazy.

[@kmcca08]

I'm a mechanic and I know mechanic's can be very critical of other mechanic's work. But you are spot on. Great work man!!

[@tothepoint4812]

Glad too finally see someone who does it right!! Yet does it as a normal mechanic would do!! Lotta these others do it by the book and every step?? Really! This guy does and knows the critical things yet still does it as we normally would!! Good job! Love a real video down too earth!!

[@1badk20]

"The Piston says Front on it, so unless you're Illiterate or a Moron, you can't get that wrong" Haha, Genius.

[@richc9503]

For some reason I have the numbers 18 and 32 stuck in my head... Great video, Thank you Rich.

[@czza2949]

gawd damn i’m so thankful for this channel. so much content

[@phaeton427]

Greatly needed bro!! Keep em comin.

[@INCC74656I]

i just did this to my 24 valve. i spent 1800.00 with full machining, over sized pistons, and such. took me 7 months from start to finish and the machining took about 3 and a half months for the machine shop to finish the block/head. they didnt do any disassembly or reassembly, just machining.

[@frankmjr6571]

I’ve watched a few of your videos, you’re a master mechanic. Great videos

[@TheCanadianBubba]

Nice work... that ring opening location tip is smart for any engine. A little detail work makes the finished job look so much better as well.

[@1melahat]

My friend just got a 91' Cummings and it needs some TLC. This video is indispensable. Thank you for sharing!

[@chickmagpunk]

Master at work here, thanks for the vids good sir and god bless!

[@igorsanchez408]

Your editing was awesome. Straight to the point! Bam... Not even click bait. Thanks pal.

[@ashleemoore9460]

best injector puller i have seen on youtube. also great video!!!

[@DJCallitquits]

Awesome video as always! Learned a lot. Thanks!!

[@Hboysoutdoors]

i really like the detail you make things very easy to understand

[@D.P.MorrisConstruction]

Can’t wait till this spring, built my dream garage last summer now I gotta build my dream Cummins swapped truck.

[@nicholashutter1865]

Dude I have never wrenched on an engine before and I really have half an idea what I am doing but somehow you are still so entertaining.

[@jgossy5478]

I love watching you work on diesels, I spent many years on gas engines, there isn't a whole lot different when putting them together. BTW my torque wrench is built into my arm.

[@jovanemontes80]

Man this is a very good informative how to video I dont even own a cummins engine.

[@JkCanvas]

I am looking at getting a 03-06 Ram 2500 Cummins and rebuiliding it. This will be my go to video when I start.

[@woopyass]

Canadian rear neck-beard FTW. Never a bad video from this guy.

[@ronrocheleau6303]

Love your videos I’m an old Cummins engine mechanic on highway truck engines from way back

[@glenvanbavel2094]

Great job , learned lots from your videos

[@herbertmeade348]

I am totally amazed at your knowlege and skill...if i had a cummins engine I know who I would want to work on it....

[@geraldalforte1154]

I Armando Rabino Academia student. I still focus watching the video. I'm very full knowledge. To watch a video, how to engine rebuild. To engine overhaul. Or engine assemble This time I additional my personal experience. To engine overhaul. Step by step. Install all parts, and all acce ssories

[@eastside0434]

The knowledge this guy has is impressive and would take me a lifetime to learn.

[@jackhawez10]

This was a great series, thanks man

[@DEBOSSGARAGE]

Its not over!

[@yomoma3719]

Your fun to watch.. keep putting out good vidya's

[@rodyjperez7659]

Awesome work!

[@Digital-Dan]

Best pedagogy on KZbin. Nice.

[@Jameswerd]

Does my crows foot count as"getting the torque wrench in there? hahaha great vids man, love the detailed mechanical explanations in these videos, love the straightforward no BS approach to every job, and for god's sake I LOVE 18FT LBS!!!!!!!!!!!

[@gearhead2376]

Great video really like your channel. I am definitely a Cummins guy. I have had my mechanic shop for 25 years this year. Not saying it's wrong but I never pull the head removing or replacing the engine. Take radiator and condenser out side it in. It's wild seeing how different people do same thing different ways again really like your channel thank you and have a blessed day

[@geraldalforte1154]

I Armando Rabino Academia student I watch the video very focus in my eyes. My knowledge is additional in this time. My personal experience is add today. And I thank you.

[@johnpossum556]

That's a brilliant move bolting the engine to the stand by the side for extra clearance and work room. Never seen any one do it that way before.

[@LAZSLOSHTOWN]

Thanks for making these videos

[@andrieslingenfelder293]

Wow. U really do a decent job. Keep it up

[@flubdreload2818]

I appreciate these videos. I know a lot about gasoline engines but I’ve never took the time to do the same about diesels. I’m interested in seeing the differences between the two no matter how minor they are.

[@richarddoire2872]

Great videos Rich

[@scottbush6203]

Hey man absolutely love the show just started watching it recently. One thing im finding ridiculously funny is how many ford commercials there are with your apparent love for recent models lol. KZbin ad win/fail right there lol

[@DEBOSSGARAGE]

Ford is listening. Trying to convert me!

[@WatchWesWork]

Buy some torque adapters. Or make your own by cutting off a box wrench and welding the drive side of a socket to it.

[@alimateen7400]

Sir, I liked your video a lot and loved it And i am very happy

[@lukereynolds9907]

The new roadkill good job da boss

[@berhanegebriel3155]

Best Engine Rebuilder.

[@guccistang]

And that's why you're DeBoss!

[@growingknowledge]

Awesome video - thanks very much.

[@sunman12345678]

Sweet video brother, I working on Cummins.

[@Coralrockplumbing]

thank you great video and good details!

[@tonystankus8835]

Great videos man 👌

[@darktrooper4]

another trick for pulling injectors is a piece of PVC piping that fits over the injector body, a washer that fits over the pvc and allows the injector end to go through and a nut that fits the threads on the injector. worked well for me, love how simple these engines are.

[@battlefinder]

A 2nd gen dodge ram lug nut is the same thread pitch as the injector lines. You can use a cut socket and a lug nut to pop them out, plus the lug is likely tapered making it even easier

[@RipleyD1]

Why i love my Gear Wrench ratchet Wrenches but taking stuff out old school is always fun

[@SteveRivett]

Great video. I would like to add a few things which I was taught. One is to clean the cylinder bores with ATF on white paper towels. Do this until the towels come out pink with no dirt. Another is to test the ring gaps deeper in the bore where the piston is pushing sideways or at least check the bore diameter down there. Lastly, I haven't seen the Cummins spec but it seemed that the honing angle was a bit much. When I went to high school we got to tear down, measure, and re-assemble Ford inline 6s. It was great! If a student acted up too much they got to bore a cylinder oversized. Great video, just food for thought.

[@Twoholesofman]

Sweet video. Subscribed.

[@jerrymarshall2095]

I hate working on cars period,i guess cause i drove piles as a young man and had alot of bad experiences workin on em,and this was when u could change a fuel pump in 5 mins.i have a 12 v and wondered how much it cost to have it overhauled,which led me to these video.iv become addicted to em now.very well done.i could sit and watch him work on the cummin all day,as long as i dont get greezy.ha ha

[@1juggernaught]

Awesome mechanic!

[@trevorburton2718]

Ex mechanic here from way back. Looks like a nice job. You can put straight edge on the head and check for any warping. An old trick is to put two head gaskets on if the head has been ground more than once.

[@Phil00661]

Thanks for a great video

[@Ticdaniel]

Great build

[@WBOS72]

Another excellent vid Rich. I love the simplicity of the B series Cummins. Next time you are near a Car Quest, stop in and check out Klondike Brake cleaner. A case can be had cheap, always on sale.

[@DEBOSSGARAGE]

I have never seen a car quest here in Canuckland

[@WBOS72]

DEBOSS GARAGE Caledonia or Grimsby. I saw a 6 pack in the Bradford Carquest when I stopped in for some parts.

[@corythomas4427]

3M 8880 from Amazon, 24 cans, $80 USD

[@Stickerslapper]

Your in canada and already working outside!!! We lucky folks in minnesota are still getting pelted with snow! 😄😄

[@DEBOSSGARAGE]

an inch of snow here today!

[@timarvan3187]

Hi had 5.7 gm diesel junk big time put 350 olds gas engine worked good. Had a couple 6.5s blew one 94 dually and 95 3/4 2wd not bad but low on power. Also started having numerous issues with 05 duramax traded on 04 Yukon with 5.3 and 05 Silverado 5.3 z71 simple to repair and affordable to run. Tim

[@yako0000]

also thanks for the videos. i know its a pain in the ass to make a video as you're trying to do a job but it's really cool to see a cummins tear down and rebuild. or anything for that matter.

[@ivankukhar2369]

This guy cracks me up

[@canadacatalyst]

Here we go!

[@davidpacheco3555]

Great video

[@blakemoore5960]

My dad bought a 1995 12 valve 5 speed 4x4 brand new at the end 1994 and all it has ever seen for oil is chevron delo 400 and sometimes it has had the Lucas oil stabilizer. It is only at 215,000 miles now but it has never had an issue at all when it comes to the engine

[@2ndspingarage]

Bias plies sent me here and im not disappointed!

[@StrokerDiesel]

Great Video !!!!

[@thepostman69]

Rick! Good trick for the kdp is to drive it in and center punch it and the case around the hole. That way it's free and no extra metal to ever possibly fall through the gears

[@DEBOSSGARAGE]

I have done that on my own truck. I don't want to risk telling people to hit their timing cover and telling me they cracked it. I'm glad I'm not the only one though. There is some footage of this dowel almost all the way out when I first opened it up

[@Pete-from-Tn]

Crows foot and Torque Wrench can get to the bolts. But then again test a few with wrench and Torque values. Then know how much to use. Enjoyed the video, wish my VP44 had a P pump.

[@Koshunae]

The best thing dodge ever decided to do was put a tractor engine in their trucks. I don't know why manufacturers don't do this regularly.

[@GreyFox2000]

Koshunae EPA mandates and the state of California

[@BarnStangz]

My 1991 Mitsubishi Fuso FG is basically a tractor engine, they just last forever, like this Cummins.

[@MLGXBOXPRO]

Don't forget the VW ALH varients. They used them as industrial engines (AFD). Last long after the rest of the VW falls apart.

[@Koshunae]

The 6.9 idi and 7.3 of the Ford that were built by IH would also last until way after the rest of the truck rotted.

[@BarnStangz]

@ Koshunae; Very true, I have a 7.3 in an old Ford that is still kicking, has almost 200K on the ticker...

[@douglaslambert6109]

Like how you end the film! Sweet!! With a mmmaaaww;)

[@fionanokelly]

very nice job!!

[@dfcvda]

picking up an ex library council bus to convert only reason why i got was cos engine is mint,the engine you have here.. actually its solid so I wont scrap the shell anyway good video. I`m in England and do everything on my own im 55

[@robertmatthews2776]

Love this Thanks GOD BLESS

[@truckcampertraveler7369]

bad ass thanks man !

[@ryanj4423]

The few people who gave this a thumbs down, need to be dropped in the middle of the Atlantic.

[@DEBOSSGARAGE]

Powerstroke owners who already know how to build engines due to having to rebuild their PS evey 100 000km.

[@ryanj4423]

DEBOSS GARAGE , haha. the mighty powerstroke! I love my diesels. I enjoy my duramax, that being said, I respect the 5.9. The simplicity of them makes me want to throw one in a old crew cab, square body, 2500 chev I bought off of kijiji. This video series is much appreciated, and is very helpful and indispensable to d.i.y.ers like myself and others who watch. Keep up the good work sir! One day I'll see if you have some time for a lml duramax egr delete/dpf removal show. (50k more to go before warranty is off!)

[@malcolmyoung7866]

Shouldn't that be 'P of S'??

[@dileepa505]

Said it Perfect brother....

[@moderngod1]

DEBOSS GARAGE ahahahah I know too many people like this 😭😭