Ugh..
Spent all afternoon yesterday putting a battery in my diesel pickup--a group 78 Interstate got for $10 at a flea market,the day I was stranded there after I stupidly left my parking lights on for 4 hours,back in late October I think..hoping it was good enough to get my truck jump started ,but a good samaratin helped me start it by jumping his truck to mine..
The battery I bought wasn't installed or used until I got it in yesterday--I had put the charger on it a few times ,and it seemed fully charged already,so I decided to gamble it was as good as the seller claimed and put it in the truck..
The batteries that were in it have been there since I got the truck in 2003,two Duralast group 74's that were likely a few years old before they were put in the truck,they came from a salvage yard,used..so they are beyond "done".
As soon as it got under 40 degrees, the truck barely cranked fast enough to start,then even after charging them,they still wont whip it over well enough..might be only one is junk and its draining the other one down,so before I trade them for cores or scrap,I'm going to put a load tester on them first..
So after balking at the prospects of paying well over $100 each for new batteries,I decided to try the Interstate first..after I hooked the cables to only that battery,and the truck fired right up!..so maybe it'll live..
I don't feel the truck is worth paying $200+ bucks for new batteries..
I have another red top Duralast group 74 that is a few years old,I got when a friend junked a Celebrity..plan to install that one today,on the drivers side..
I know your supposed to have a "matched pair",but those old batteries were not identical,one was a Duralast "Gold" and the other wasn't,but they were about the same size overall..
Well,it took me 4 hours to get the battery in--I had doubts the battery trays will be able to withstand the weight on both sides--the inner fenders are swiss cheese and have no real strength--the bolts on the tray going to the fender is about all that are doing anything..but I am in not able to buy or install new inner fenders-- now feel the truck may not be worth the effort to, even if I could..
I had to invent a new hold down for the larger battery--the single bolt clamp deal GM used won't cut it with a heavy battery and the tray not having all its sides intact..I used an old serpentine belt--cut it to length , bolted it to the front fender,and punched two holes in it and used a longer threaded rod in the bolt hole where the original clamp went..seems plenty strong--I don't want the battery moving when I ram snowbanks and shorting out!..
When I got the truck to fire up,I had the hood open--saw clouds of exhaust smoke belch out from the passenger side ,and the engine sounded lopey,like a gas engine that had been flooded--heard a "pop-pop-pop" every so often when it misfired,and I looked where the smoke was coming from,and assumed its coming from a chunk of the exhaust manifold that rotted off or blew out,I cant see well where its coming from,its on the bottom.. --the exhaust manifold has been crusty as hell for years,and I am praying its not a head gasket that blew--
--after it warmed up some it cleared out and stopped "popping"..so I'm hoping its just an exhaust leak,not the head gasket..
I had to put a used exhaust manifold on the drivers side a year or two ago,and I swear it took 10 years off my life span to do it..
As most 6.2 owners here know,the exhaust manifold bolts align directly with the frame rail--so no ratchet or sockets can be used,unless you try jacking the engine up off the mounts--even then its a toss up if you could use one then..
Doesn't matter much on my truck,all the bolt heads are round as rivets now, they are so rotted..so the torch or a sawsall is the only tool that will work..
When I did the drivers side exhaust manifold,I had to torch off every bolt head,torch slots in the manifold around the bolts,then hammer it off until it came free of the bolts--then cut off the bolts close to the manifold,and struggle to thread the thing out of there--and weld nuts on each "stud" in order to remove them,hopefully without them snapping off in the head..
Costed me $50 in oxogen and propane to cut it off..and hours of agony,bending over the fender..
It only took me 3 afternoons from noon till dark to complete the job,and I swear I have never fully recovered from doing it..luckily all the bolts came out--finding new ones was a 10 mile trip to three hardware stores,costed almost $20..not many metric bolts in stock around here anywhere..
I am not likely to be able to replace this manifold myself,I have a spare one,but no one I know wants any part of that job for less than $500 locally either..including my friend,he hates working on rusted junks like my truck,and either refuses such jobs,or quotes a outrageous price hoping the customer will go elsewhere..
I doubt I can braze or weld the manifold either--leak is on the bottom,and its so thin and flakey it will probably just blow a bigger hole--like the one on the drivers side did when I tried patching it that way..
It figures this happens now,when winter sets in,and I need the truck the most..
I'm really getting sick of the 6.2--been tempted to get those two 307's I bought earlier this year running ,and if either one runs decent,yank that p-o-s out before it decides to snap the crank, or the oil pan lets all the oil come out when my bondo & rtv patch job fails..it's been holding up OK so far,but its just a matter of time before that fails..
I think it'll be easier to swap another engine in it, than replace the exhaust manifold and oil pan,plus it'll still have other potential failures waiting to happen--the rusty fuel injector lines,the vacuum pump that doesn't work well enough to get the TH400 to shift properly,and more...and most of all,I'm sick of cold start issues,replacing glow plugs,dead batteries..tired of paying more for diesel fuel and getting the same MPG as a gas engine too..
I think its time to make this a "yard truck" and either use it only around the yard--or take it all apart, and fix everything wrong with it--only thing that's keeping me from doing it, IS me..
The past week or two I've been having irregular heartbeats at night lying in bed,and multiple other health issues,and this seems "serious"..
I may end up in the ER,or worse, feeling like I do now,if I attempt doing the manifold replacement or an engine swap...worst time of the year to start a project too..
I'm in no condition to do all that work--I'll be lucky(and happy), to just get the other battery in it today...and hope they pan out ,and I don't have to buy two more new or used ones and start over..
Spent all afternoon yesterday putting a battery in my diesel pickup--a group 78 Interstate got for $10 at a flea market,the day I was stranded there after I stupidly left my parking lights on for 4 hours,back in late October I think..hoping it was good enough to get my truck jump started ,but a good samaratin helped me start it by jumping his truck to mine..
The battery I bought wasn't installed or used until I got it in yesterday--I had put the charger on it a few times ,and it seemed fully charged already,so I decided to gamble it was as good as the seller claimed and put it in the truck..
The batteries that were in it have been there since I got the truck in 2003,two Duralast group 74's that were likely a few years old before they were put in the truck,they came from a salvage yard,used..so they are beyond "done".
As soon as it got under 40 degrees, the truck barely cranked fast enough to start,then even after charging them,they still wont whip it over well enough..might be only one is junk and its draining the other one down,so before I trade them for cores or scrap,I'm going to put a load tester on them first..
So after balking at the prospects of paying well over $100 each for new batteries,I decided to try the Interstate first..after I hooked the cables to only that battery,and the truck fired right up!..so maybe it'll live..
I don't feel the truck is worth paying $200+ bucks for new batteries..
I have another red top Duralast group 74 that is a few years old,I got when a friend junked a Celebrity..plan to install that one today,on the drivers side..
I know your supposed to have a "matched pair",but those old batteries were not identical,one was a Duralast "Gold" and the other wasn't,but they were about the same size overall..
Well,it took me 4 hours to get the battery in--I had doubts the battery trays will be able to withstand the weight on both sides--the inner fenders are swiss cheese and have no real strength--the bolts on the tray going to the fender is about all that are doing anything..but I am in not able to buy or install new inner fenders-- now feel the truck may not be worth the effort to, even if I could..
I had to invent a new hold down for the larger battery--the single bolt clamp deal GM used won't cut it with a heavy battery and the tray not having all its sides intact..I used an old serpentine belt--cut it to length , bolted it to the front fender,and punched two holes in it and used a longer threaded rod in the bolt hole where the original clamp went..seems plenty strong--I don't want the battery moving when I ram snowbanks and shorting out!..
When I got the truck to fire up,I had the hood open--saw clouds of exhaust smoke belch out from the passenger side ,and the engine sounded lopey,like a gas engine that had been flooded--heard a "pop-pop-pop" every so often when it misfired,and I looked where the smoke was coming from,and assumed its coming from a chunk of the exhaust manifold that rotted off or blew out,I cant see well where its coming from,its on the bottom.. --the exhaust manifold has been crusty as hell for years,and I am praying its not a head gasket that blew--
--after it warmed up some it cleared out and stopped "popping"..so I'm hoping its just an exhaust leak,not the head gasket..I had to put a used exhaust manifold on the drivers side a year or two ago,and I swear it took 10 years off my life span to do it..
As most 6.2 owners here know,the exhaust manifold bolts align directly with the frame rail--so no ratchet or sockets can be used,unless you try jacking the engine up off the mounts--even then its a toss up if you could use one then..
Doesn't matter much on my truck,all the bolt heads are round as rivets now, they are so rotted..so the torch or a sawsall is the only tool that will work..
When I did the drivers side exhaust manifold,I had to torch off every bolt head,torch slots in the manifold around the bolts,then hammer it off until it came free of the bolts--then cut off the bolts close to the manifold,and struggle to thread the thing out of there--and weld nuts on each "stud" in order to remove them,hopefully without them snapping off in the head..
Costed me $50 in oxogen and propane to cut it off..and hours of agony,bending over the fender..
It only took me 3 afternoons from noon till dark to complete the job,and I swear I have never fully recovered from doing it..luckily all the bolts came out--finding new ones was a 10 mile trip to three hardware stores,costed almost $20..not many metric bolts in stock around here anywhere..
I am not likely to be able to replace this manifold myself,I have a spare one,but no one I know wants any part of that job for less than $500 locally either..including my friend,he hates working on rusted junks like my truck,and either refuses such jobs,or quotes a outrageous price hoping the customer will go elsewhere..
I doubt I can braze or weld the manifold either--leak is on the bottom,and its so thin and flakey it will probably just blow a bigger hole--like the one on the drivers side did when I tried patching it that way..
It figures this happens now,when winter sets in,and I need the truck the most..

I'm really getting sick of the 6.2--been tempted to get those two 307's I bought earlier this year running ,and if either one runs decent,yank that p-o-s out before it decides to snap the crank, or the oil pan lets all the oil come out when my bondo & rtv patch job fails..it's been holding up OK so far,but its just a matter of time before that fails..
I think it'll be easier to swap another engine in it, than replace the exhaust manifold and oil pan,plus it'll still have other potential failures waiting to happen--the rusty fuel injector lines,the vacuum pump that doesn't work well enough to get the TH400 to shift properly,and more...and most of all,I'm sick of cold start issues,replacing glow plugs,dead batteries..tired of paying more for diesel fuel and getting the same MPG as a gas engine too..
I think its time to make this a "yard truck" and either use it only around the yard--or take it all apart, and fix everything wrong with it--only thing that's keeping me from doing it, IS me..
The past week or two I've been having irregular heartbeats at night lying in bed,and multiple other health issues,and this seems "serious"..
I may end up in the ER,or worse, feeling like I do now,if I attempt doing the manifold replacement or an engine swap...worst time of the year to start a project too..

I'm in no condition to do all that work--I'll be lucky(and happy), to just get the other battery in it today...and hope they pan out ,and I don't have to buy two more new or used ones and start over..


