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6.2L & np208 questions

onetonjimmy

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south florida
Hey ya'll- I just bought my next toy and was looking for a few answers/suggestions/experiences. I've got 30 yrs experience spinning wrenches and am now on vehicle #85. I'm used to big-blocks, th400's, and 205's. I'm getting lazy in my old age and am considering leaving this one stockish. I know diddly about diesels, and chain drive transfer cases. So- I went and bought a military m-1028 that is supposed to run great, drive great, and everything works like it's supposed to. It should be here by the end of the month, and I'll know for sure. I had one once, and was underwhelmed by it's power. I bought it solely to rob the running gear for the Jimmy that shows as my avatar. I tried asking the same questions on another site, and them folks are waaaaay too tightly wrapped for me. So, is it a dependable combo? What are the problem areas? okay as a daily driver? I saw a lot of postings relating to glow plug stuff and starting issues. What diesel/military specific things need improvements? I thought I'd try it stock before doing the BBC swap( I've got everything from air cleaner to oil pan ), but dependability & reliability take priority over learning a new engine design, so if this is a problem child, a cubic inch injection is in order. Any tips will help. As to the np208- how durable is it? I'll be running the stock 4.56's with locker/trac-lock combo and the tallest tire I can, without a lift kit. I'm looking more for bomb proof than latest/greatest doohickey widgetmobile. Would I be better off with a 205? Not going to rock climb or mud bog, but will eventually be pulling a large travel trailer. again- any info is beneficial thanks!:confused::confused::confused::confused:
 
Welcome to the diesel club! I have 3 6.2 trucks, and I have found them to fit my needs quite well. They make awesome daily drivers.

The 6.2 engine is dependable and fairly simple, although it has some diesel-specific quirks that seem odd to some. They're not an overly strong engine if you want to build a drag racer, but in stock form they are a good candidate for a bomb-proof truck build. They won't produce the power of a big-block under any normal circumstances, and they like to spin slow. At 3000 RPM they're not much more gutsy than they are at 1800RPM (and they sound terrible, IMO). A simple mod you can do to increase power output is grabbing a turbine setup from a later 6.5TD engine (the 6.5 is nearly the same engine as a 6.2, over-bored with a turbine and a lower compression ratio). I highly recommend this if your goal is towing. The turbo-diesel setup provides noticeably more power, and I would think it would give a 454 a run for its money, though I've never set them side-by-side. On second thought, I have pitted a 454 against my Suburban (when I was loaded to about 8,000 lbs), and my truck beat the pants off the other one. But that was only because the other truck was a P30 weighing in at 14,500 pounds. :rolleyes:

The "stock" 4.56 gears in an M1028 (w/o overdrive) are not well suited to a 6.2 diesel, unless your goal is low-speed crawling. On the other end of the spectrum, my K10 has 3.08 gears, 29" tires, with overdrive. 55MPH is about 1400RPM, and 65MPH is about 1625RPM. This is about perfect for non-trailer driving. My Suburban has 3.73 gears, 31" tires, with overdrive. 55MPH is about 1550RPM, and 65MPH is about 1800RPM. This is about perfect for trailering (although I think it's too much gear for how I usually drive it). If you were able to get 33" tires underneath the M1028, 55MPH would be about 2550RPM, and 65MPH would be about 3000RPM. Doable, and obviously the M1008-series trucks all came that way, but they really aren't happy at highway speed. :doah:

One other benefit to keep in mind is that 6.2 engines are capable of really good mileage when set up properly. That K10 with 3.08s will regularly pull 23-24MPG at 55MPH, and 21-22MPG at 65MPH (sometimes higher). So the potential for a (relatively) cheap daily driver is there, if that's what you are interested in with this stockish vehicle.

I wouldn't worry about the NP208 if you aren't abusing the truck off-road. Plenty of folks hit trails of all types with NP208 cases.

Problem areas: I don't think the engine has any particularly troubling issues, just a few quirks. If you run a mechanical fuel pump AND suck an air bubble in your fuel line you are stuck cranking the engine until the bubble passes (there are procedures to help both avoid and resolve this). Glow plug controllers often fail, but they are easily fixed, or even more easily bypassed (I wired up a momentary-contact switch on 2 of my trucks). 6.5TD engines under heavy trailer loads can overheat and crack heads (so buy a pyrometer if you go with the turbo setup). Square fuel filter assemblies can sometimes leak (though mine never have). Glow-plugs burn out (particularly older-style plugs), and the engines are hard (or impossible) to start without them. Low-temperature starting may require a block heater (pretty sure you won't encounter that in South Florida). Overall these engines don't have much that can be messed up. Outside the injection system they are dirt simple (and the injection system isn't bad either, it's just different). The only electrical requirement is a single 12V wire run to the fuel-shutoff solenoid on the IP. The one piece of smog equipment (EGR) will already be gone from your military engine.

The military trucks have some wiring differences, but other aspects of the trucks are identical to civilian models, though they are stripped-down models.
Wiring differences include:

Blackout lights (marker led lights on both bumpers and a small covered headlight in the grill)
A second ground-isolated alternator
The truck's two batteries are attached in series instead of in parallel
Starter motor runs on 24V instead of 12V
Glow plug controller operates on 24V (but plugs still run on 12V).
24V jumper cable receptacle installed in grill

Everything except the starter and the input to the glow plug controller operates on 12V. Aside from the 2 extra switches, ammeter, and dual generator lights on the dash, the truck is like any other Chevy diesel truck.


These engines are often a love-or-hate relationship. If you want speed and high-end power, this is not your engine. If you want high mileage this is just about the best thing out there. For everyone else (in the middle), the engine is either weird, noisy, and smelly, or awesome, torquey and cool. :)
 
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great info, thanks! My current and only vehicle is a '78 c35 454/th400/3.73 Detroit locker that's my daily driver approximately 20mi to each way to work. I tend to drive in the 55-60 mph range( ~ 2500 rpm on my tach), for the foreseeable future, that will stay the same. The transfer case issue is resolved- leave it alone! This new to me truck supposedly has only 19k miles and was a ? contact maintenance? truck all it's life @ Ft. Benning, Ga., so maybe it will be awhile before any issues arise. The auction picture barely shows what looked like a bed size mounted toolbox with these d-ring things mounted at all 4 corners for tie downs. Owner says he has all maintenance records to go with it. I've got some reading to do, but I think I'll try this diesel thing, and have the spare/redundant glow plug stuff on stand by. I'm pretty sure I can fit 32.5" - 33" tires w/o lift and no cutting. We'll see.......... If you're interested-see Ebay auction # 181709419953
 
great info, thanks! My current and only vehicle is a '78 c35 454/th400/3.73 Detroit locker that's my daily driver approximately 20mi to each way to work. I tend to drive in the 55-60 mph range( ~ 2500 rpm on my tach), for the foreseeable future, that will stay the same. The transfer case issue is resolved- leave it alone! This new to me truck supposedly has only 19k miles and was a ? contact maintenance? truck all it's life @ Ft. Benning, Ga., so maybe it will be awhile before any issues arise. The auction picture barely shows what looked like a bed size mounted toolbox with these d-ring things mounted at all 4 corners for tie downs. Owner says he has all maintenance records to go with it. I've got some reading to do, but I think I'll try this diesel thing, and have the spare/redundant glow plug stuff on stand by. I'm pretty sure I can fit 32.5" - 33" tires w/o lift and no cutting. We'll see.......... If you're interested-see Ebay auction # 181709419953

Nice find! Looks like you have a dandy. 19k miles of 1/2-mile trips across army bases probably isn't like having a civilian truck at 19k miles. But quite nice if that turns out to be actual mileage (I'll prolly never know whether my M1009 has 40k or 140k or 240k miles).

My guess is that your trucks would be happier if you swapped axles, so the diesel had the 3.73 gears and the 454 had the 4.56 gears. Lack of O/D, combined with 4.56 gears, can lead to an unhappy 6.2 engine. But you'll figure it out.

For the glow plugs, they're easy to check with an ohm-meter. And, as there are 8 of them, you will have warning of them failing (one by one). You'll develop an issue of starting on 7 cylinders...and then 6...and then 5. Down in your area you can probably start just fine on 5 glow plugs. It's been about 15,000 miles since I first diagnosed my K10 with 2 failed glow plugs (and likely more now), but it still starts reliably, so I haven't bothered replacing them. Although the Suburban (with 8 new plugs) does start more smoothly at cold temperatures (below 30*F). So it's not something that will suddenly strand you on the side of the road. GP controller failure, OTOH, can strand you (when you suddenly have zero glow plugs), so I would at least get comfortable jumping that circuit in the case that it did fail while you were out and about with a cold engine. Not all that likely to happen, but certainly possible. Otherwise there's not much to fret about with these engines. They're pretty simple, overall.

Keep us posted on how it turns out! :popcorn:
 

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