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I’m gonna start this build and hopefully my son will continue posting after I get it where I want it to keep it going!
After two months owning this thing and all it has been through, finally got it going! So now the build can start!
First task was starting the motor. After hours and hours of research and lots of help from members and 2INSANE, ended up replacing the GP solenoid, adding an electric fuel pump, new batteries, new fuel filter and replaced rubber lines, found a J code intake, replaced IP and ran brake cleaner through the lines to blow all the crap out. Learned how to bleed the fuel system and she fired up! Got rid of all the EGR stuff on the motor too. She seems to run very well. Upon initial test drive, we learned Tcase was indeed messed up. Shift into 2hi and get 4lo. Everything else is neutral other than 4lo and we had to hold the shifter back as it kept popping out of gear. But we were hell bent on driving the truck that day. lol. Steering tight and engine ran great. I have another 465/208 that we planned to use in the other truck I was building for my son, so today, I got as far as unbolting that Tcase off the trans and got the bad 208 removed from the truck. Apparently no auto parts stores in town carry that gasket, so now we wait for shipping…..
When removing the 208, I saw the PO used gear oil in the Tcase!!!! SMDH.
But underneath this truck is coated with a thick layer of mud. Another clue as to why it was parked.
While I wait for my new gasket, I’m gonna get a GP switch installed and wire the fuel pump permanently. I found a switch I like on Amazon that was intended for a bobcat and mount in the dash.
kinda leaning towards 3/4 ton axles and H1 wheels painted white with 90s chrome caps over them. There’s a build on here I saw few years ago and remembered how cool that looked with a white truck. Can’t remember who it was but that build was awesome. I still have a CUCV grill and bumper I was gonna use on the other truck that I may use on this truck. I also have a chrome warn winch bumper as well.
I’m not opposed to keeping it a K10 and use the 15” white steel wheels and hub caps but I’d like to run 37s and at least have 4.10s. Does anyone on here have pics of their rig with 15” steelies with caps and 35-37s? I’ve been talking to another member here and tryin to buy his ORD springs and 4” shackle flip with zero rates to use for this truck. I’ll also do crossover and XJ shaft and all the necessary upgrades similar to my blazer and my crew cab. Want my son to be able to enjoy this truck for years to come and have a solid rig should he ever wanna have fun in the mountains.
After two months owning this thing and all it has been through, finally got it going! So now the build can start!
First task was starting the motor. After hours and hours of research and lots of help from members and 2INSANE, ended up replacing the GP solenoid, adding an electric fuel pump, new batteries, new fuel filter and replaced rubber lines, found a J code intake, replaced IP and ran brake cleaner through the lines to blow all the crap out. Learned how to bleed the fuel system and she fired up! Got rid of all the EGR stuff on the motor too. She seems to run very well. Upon initial test drive, we learned Tcase was indeed messed up. Shift into 2hi and get 4lo. Everything else is neutral other than 4lo and we had to hold the shifter back as it kept popping out of gear. But we were hell bent on driving the truck that day. lol. Steering tight and engine ran great. I have another 465/208 that we planned to use in the other truck I was building for my son, so today, I got as far as unbolting that Tcase off the trans and got the bad 208 removed from the truck. Apparently no auto parts stores in town carry that gasket, so now we wait for shipping…..
When removing the 208, I saw the PO used gear oil in the Tcase!!!! SMDH.
But underneath this truck is coated with a thick layer of mud. Another clue as to why it was parked.
While I wait for my new gasket, I’m gonna get a GP switch installed and wire the fuel pump permanently. I found a switch I like on Amazon that was intended for a bobcat and mount in the dash.
kinda leaning towards 3/4 ton axles and H1 wheels painted white with 90s chrome caps over them. There’s a build on here I saw few years ago and remembered how cool that looked with a white truck. Can’t remember who it was but that build was awesome. I still have a CUCV grill and bumper I was gonna use on the other truck that I may use on this truck. I also have a chrome warn winch bumper as well.
I’m not opposed to keeping it a K10 and use the 15” white steel wheels and hub caps but I’d like to run 37s and at least have 4.10s. Does anyone on here have pics of their rig with 15” steelies with caps and 35-37s? I’ve been talking to another member here and tryin to buy his ORD springs and 4” shackle flip with zero rates to use for this truck. I’ll also do crossover and XJ shaft and all the necessary upgrades similar to my blazer and my crew cab. Want my son to be able to enjoy this truck for years to come and have a solid rig should he ever wanna have fun in the mountains.
Got the GP switch installed and lift pump wired in. Don’t have to pop the hood and hot wire it anymore! lol.
Just patiently waiting for the Tcase adapter gasket to show up…..
BTW I have a brand new mechanical lift pump and the push rod out of the block if anyone is interested let me know. I’ll prob post in the for sale section.
Just patiently waiting for the Tcase adapter gasket to show up…..
BTW I have a brand new mechanical lift pump and the push rod out of the block if anyone is interested let me know. I’ll prob post in the for sale section.
looks like a clean install
Thanks! I search everywhere for a GP switch that looked close to something “factory like” and found this on Amazon it’s for a bobcat. I thought about putting it to the left of the headlight switch since there’s no vent, but may use that for a switch panel later on.
Nice trucks! Love the glow plug switch.
I will take that lift pump off your hands. I would like to have a spare. Pm me.
Also, following your build as I am new to the 6.2 realm with a 85 M1009 I purchased this spring. (Check my build thread on it lol).
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Awesome thanks! I’ll PM you.I will take that lift pump off your hands. I would like to have a spare. Pm me.
Also, following your build as I am new to the 6.2 realm with a 85 M1009 I purchased this spring. (Check my build thread on it lol).
1985 Chevy M1009 (CK5 build thread part 2)
This thread is for the general discussion of the Item 1985 Chevy M1009 (CK5 build thread part 2). Please add to the discussion here.ck5.com
I’ve been relentlessly researching the 6.2 since I’ve acquired this truck. I’m beginning to really love them now that I understand them more. Haha. Maybe because they are just different and it’s cool that not many people have them driving around anymore. Everyone has a 350, (I have a vortec 350 in my blazer…..) but I have one square crew cab with a Cummins 12 valve and another with a 6.2. My son is super excited about it. In the other truck we were building for him before we lost it, I was on the hunt for a 4bt.
When he heard this 6.2 fire up for the first time, I think he fell in love.
Gasket came in today, but I won’t have time to put the transfer case in till possibly Friday or Sunday. Kills me to wait.
I like my 6.2L. Pretty gutless but I specifically searched for one when I got it. Gets decent mileage and its mechanical fuel injection so no worries about a fuel injection swap like all the gasser guys do. Plus I'm a diesel mechanic so it's what I know.
Other 208 Tcase on, first stop was the dumpster to throw all the parts boxes and old parts away, get some diesel, Then car wash! Pulled some of the melted trim off and paint came off in a couple places. Oh well, gives it character Haha.
Got to finally take her out on the road and see how well she runs. Runs great! Gonna need new tires soon.
The 6.2 definitely lacks power on a steep grade headed up to my house, but overall happy with it. It will be a great highschool truck for my son. Actually he started up his CK5 account today OlSmokeyK10.
Next up on to-do is change all the fluids, new belts. I bought an EGT gauge from auto meter that kinda resembles the factory gauges. Any suggestions where to put it that looks factory-ish? Only place I can see is where the AC vent would go on the dash by the light switch?
Also, I’m buying a lift setup from BTracy with ORD front springs. I’m thinking I’m going to order H1 wheel/tire package from TWF and have them powder coat the plates white.
We have a CUCV brush gaurd and bumper that survived the fire. I’ll be on the hunt for a decent CUCV grill if anyone has one. Maybe even factory will work and bezels.
Just so happy this thing is running and driving. Now the fun begins,….
Got to finally take her out on the road and see how well she runs. Runs great! Gonna need new tires soon.
The 6.2 definitely lacks power on a steep grade headed up to my house, but overall happy with it. It will be a great highschool truck for my son. Actually he started up his CK5 account today OlSmokeyK10.
Next up on to-do is change all the fluids, new belts. I bought an EGT gauge from auto meter that kinda resembles the factory gauges. Any suggestions where to put it that looks factory-ish? Only place I can see is where the AC vent would go on the dash by the light switch?
Also, I’m buying a lift setup from BTracy with ORD front springs. I’m thinking I’m going to order H1 wheel/tire package from TWF and have them powder coat the plates white.
We have a CUCV brush gaurd and bumper that survived the fire. I’ll be on the hunt for a decent CUCV grill if anyone has one. Maybe even factory will work and bezels.
Just so happy this thing is running and driving. Now the fun begins,….
Haven’t updated in a while…..
Couple weeks after driving her and enjoying her, shut it off one night and next day would not start. Purged the fuel system again, cranked and cranked, literally tried everything. I wasn’t getting fuel out the GP holes so I assumed the replacement IP went bad. Ordered a new IP and injectors, return lines, and it sat for a few months while I got busy with my property and just didn’t have time to mess with it.
Last month, I finally had a weekend to replace the fuel system, and after priming I was finally getting fuel out the GP holes. But the truck still wouldn’t start. Spent days cranking and trying different things. Tested all GPs, no air in return lines, had good pressure, just frustrating. I’ve come to the conclusion that the motor is possibly low on compression and doesn’t have enough to start. In a last desperation attempt, I even sprayed starting fluid in the intake as I was already at a loss. The truck kind of coughed, but never wanted to start. I ended up burning up the starter and just gave up on it.
I’m at a point to where I don’t know if I wanna put another 6.2, I liked the old diesel sound and how it made the truck unique. I already have all this money invested in a new IP, electric Lift pumps, filters, GPs, Injectors, J code intake, GP solenoid, EGT gauge……. I haven’t been able to find another 6.2 within couple hundred miles for sale that runs to just drop in.
Other option in to put the vortec 5.7 from my blazer in this truck since I acquired a 454 for it anyway.
Just kinda torn at the moment. Although gutless, the 6.2 is still a pretty cool motor.
If anyone around NM has a good running 6.2 I’d be interested. It’s been snowing pretty hard lately and it’s gonna have to sit till weather warms up a little.
Couple weeks after driving her and enjoying her, shut it off one night and next day would not start. Purged the fuel system again, cranked and cranked, literally tried everything. I wasn’t getting fuel out the GP holes so I assumed the replacement IP went bad. Ordered a new IP and injectors, return lines, and it sat for a few months while I got busy with my property and just didn’t have time to mess with it.
Last month, I finally had a weekend to replace the fuel system, and after priming I was finally getting fuel out the GP holes. But the truck still wouldn’t start. Spent days cranking and trying different things. Tested all GPs, no air in return lines, had good pressure, just frustrating. I’ve come to the conclusion that the motor is possibly low on compression and doesn’t have enough to start. In a last desperation attempt, I even sprayed starting fluid in the intake as I was already at a loss. The truck kind of coughed, but never wanted to start. I ended up burning up the starter and just gave up on it.
I’m at a point to where I don’t know if I wanna put another 6.2, I liked the old diesel sound and how it made the truck unique. I already have all this money invested in a new IP, electric Lift pumps, filters, GPs, Injectors, J code intake, GP solenoid, EGT gauge……. I haven’t been able to find another 6.2 within couple hundred miles for sale that runs to just drop in.
Other option in to put the vortec 5.7 from my blazer in this truck since I acquired a 454 for it anyway.
Just kinda torn at the moment. Although gutless, the 6.2 is still a pretty cool motor.
If anyone around NM has a good running 6.2 I’d be interested. It’s been snowing pretty hard lately and it’s gonna have to sit till weather warms up a little.
Yeah he was super helpful and we spent a lot of time on the phone trying different things on this motor. We both are at a loss. I’m getting fuel, GPs are working, have good fuel pressure. Just won’t start. It would puff out a little smoke couldn’t tell if it was white or grey after couple min of cranking. But not a whole lot. The last compression check I did was when he helped me get the truck running the first time. He ended up sending me a 6.5 IP and after that swap she started right up. Last compression check numbers were
Cyl 1. 280
Cyl 3. 305
Cyl 5. 295
Cyl 7. 280
Cyl 2. 310
Cyl 4. 305
Cyl 6. 320
Cyl 8. 290
Was tested on the GP hole with all the GPs out. Not sure how accurate my gauge was but it ran great when it was running. That last few days it was running the only thing I can think of was it took a little more cranking and GP cycles each time. After we first got it running again, it would take one GP cycle and she fired up. The last day we drove it I think it took 3 then she fired up. We drove it around town came home shut it off…..next morning she would not start again. I was gonna do another compression check but the starter crapped, so I’m just assuming it doesn’t have enough to ignite the diesel.
That's just really weird to go from running to not. I would definitely not assume low compression. To me it seems like a fuel supply issue. If you are still running the factory mechanical lift pump you could plumb a hose from it into a bucket or jug of fuel then make sure everything is primed and bled. Make sure timing is correct, make sure the cam and injection pump are turning and fuel is bled to the injectors. If it has a block heater then plug it in to make starting easier without completely relying on the glow plugs. I give mine a whiff of ether when it sits a long long time between starts otherwise it lights off pretty good. Better than my '99 7.3L most times. My 6.2 does smoke due to needing new injectors.
If it wont run on either I find it had to believe its a fuel issue, unless timing is way off
I know for a fact you can put a whole can of ether through a 6.0L powerstroke that has injectors with stiction issues and they won't start. 
Stiction causes the injection timing to be off on those engines.
Stiction causes the injection timing to be off on those engines.
I had added an electric lift pump before I first had the truck running. I since added a fuel pressure gauge to confirm it’s working. I even moved the lift pump to the frame rail by the tank switch and bypassed the tank switch. I’ve bled the filter, bled all the Injectors had a small dribble out of each line, I then removed all the GPs and cranked until all the holes had mist shooting out. I’ve tried to advance the IP as far as it will go just to start it. I have a clear hose on the IP and no bubbles in it. I’m really at a loss. I thought for sure starting fluid would do something but all it did was a little cough and had some black smoke out the pipes. Used a whole can as a last resort after 3-4 days of trying different things.
Too bad…. That would have me frustrated as hell.
The only thing I can think of is there has got to be air getting into the fuel system somewhere. Where is the problem?
Have you tried pressurizing the fuel tank with air? I haven’t had much luck with that method myself, but some people have found their problem that way.
Of course the starter is Focked so that needs to be fixed, how much time and money does one spend before they give up?
I think that’s the biggest reason 6.2s and 6,5s get a toss for a gasser or scrapped.
Hope you get some luck!
The only thing I can think of is there has got to be air getting into the fuel system somewhere. Where is the problem?
Have you tried pressurizing the fuel tank with air? I haven’t had much luck with that method myself, but some people have found their problem that way.
Of course the starter is Focked so that needs to be fixed, how much time and money does one spend before they give up?
I think that’s the biggest reason 6.2s and 6,5s get a toss for a gasser or scrapped.
Hope you get some luck!
That’s where I’m at, I could go buy a starter but I think I’m already over a grand in parts so far invested in the motor. I can’t even count the hours and days invested into it. My hard-headedness was hell bent on getting this motor running. I love the old school diesel and my son loves it. But at what point do I just throw in the towel. Haha. In my mind the 350 from my blazer could be done in a day, but then I have all these new parts on this motor and I’ll have to drain the tanks and convert it to gas. If I could find another 6.2 running I would buy it and swap it. I’m still hard headed about keeping it diesel and has all the badges on it. Plus I would have all these spare parts. Lol. When it was running, it ran great! Till it didn’t. Hahaha. I don’t know what else to check. I haven’t tried pressurizing the tank. I had to walk away from it as it was pi$$ing me off. I think we will continue with installing the suspension and think on this in the meantime
You didn't break the crank did you? Gotta ask.
