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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 12:09 am 
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Hello everyone. Hope you are all staying safe. Happy Cinco deMayo ! :SOMBRERO:

Got the rods and wrist pins back from the new machinist and they are excellent.

Time to bring everyone up to date. I haven't posted anything because it's all too embarrassing. :oops: Took a week off to finish the engine but that didn't work out for two reasons: Corona Virus. Wrong oil. :banghead:

Everything was going good until I started to verify the oil jets were actually hitting the holes in the pistons. Since I'd have to operate the lubrication system I used my transfer pump to push oil through the galleys with the block upside down. Unfortunately I chose the wrong jug of oil and pumped the oil with the carbon back into the engine. :banghead:

To remedy this, I started cleaning the engine with a solution of water, simple green, OxyClean and Marvel Mystery Oil. This did work but when I put new oil in the system there was very little oil pressure. So I decided to take it all apart again and start over. Stripped everything out of the block: Crank assembly, liners, freeze plugs, screw plugs, oil pressure relief valve.

Got a metal trash can filled it with water, Simple Green and OxyClean. Heated the solution for 3 hours until it started to boil then boiled the block for 2 hours more. Took it out and pressure washed it inside and out, and even in the oil galley and cooling jacket.
Image
The block fits nicely into a 30-gallon metal trash can.

Image
Having problems with my smartphone emailing pictures so I messed with the pictures to make the file smaller. No luck. Turned out I just had to turn the phone off and back on. That fixed it. Sorry about the crappy images.

Image
The water was yellow from the paint.

Image
Still wasn't sparkling clean, so I decided to Electrolyze it.

Already have a large plastic trash can so I fitted two construction stakes on either side for sacrificial anodes. Filled with water, Simple Green and OxyClean and started a 24-hour electrolyzing process. Next day the water was black and had a rusty grunge floating on the surface.
Image
Highlighted the battery charger clamp connections in MS Paint. It's important to connect the positive (+) lead to the sacrificial anodes and the negative (-) lead to the engine block. Electricity travels from - to + and the rust goes the other direction and collects on the positive anode(s).

Image
The inspector was asleep on the job.

Image
Power washed the block and most of the paint came off, and most of the carbon came off the cooling jacket around the pistons, and the calcium build-up on the rest of it.

I think I'll electrolyze it for another 24 hours to see if the rest of everything comes off.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Last edited by CaptainDean on Wed May 06, 2020 11:04 pm, edited 3 times in total.

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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 9:10 am 
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Posts: 365
Location: Australia
The cat looks dead! sure you didnt find it in the water jacket!
You are very brave doing that sort of clean.
Are all machined surfaces protected?
Best not try it on head. dissimilar metals tend to setup their own galvanic call & inserts become loose. Aluminum soon disappears with caustic solutions.

Hope you didnt get CV19.
Stay Safe!

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Australian KJ CRD 2006


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 9:15 am 
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Posts: 193
Location: Central Iowa, USA
I was a little sad to see the yellow paint coming off of the engine. Dead cat - seen enough of those- not sad at all.

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2005 KJ CRD ~150K
V6 Airbox, Samco Hoses, Provent
Weeks 1&2, Thrush Glasspack
Facet Fuel Pump, Secondary Fuel Filter
ARPs, 188 Degree Thermostat
GDE Eco Tune Full Torque
OME 1.5", JBA A-Arms and Top Plates
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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 12:02 pm 
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Never ever Hot tank an aluminum head or any aluminum part in any kind of caustic solution, it will eat up the aluminum.
First rule we learned years ago in an automotive machine shop.

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05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Sasquatch BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 bld.fan/NAPAHDClutch
IronrockArms/wwdieselMount


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 11:38 pm 
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layback40: You cracked me up, "...did you find the cat in the cooling jacket..." I laughed out loud.

WWDiesel, layback40: Thanks for the warning about aluminum in the hot, caustic solution. Machine shops use highly caustic solutions in their tanks, but all I have are Simple Green (light acid) and OxyClean (Sodium Percarbonate and Sodium Carbonate. These substances form oxygen and hydrogen peroxide when mixed with water). Both seem gentle but I don't think I'll attempt electrolyzing the aluminum parts. Thanks for the warnings.

My wife was envisioning the block disintegrating into a pile of sand as though Marvin the Martian shot it with his Disintegrating Ray Gun.
Image

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Thu May 07, 2020 9:24 am 
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Joined: Sat Oct 13, 2018 10:09 pm
Posts: 365
Location: Australia
Its good to see you still have a sense of humor!
The drama you have gone through would have had many slashing their wrists!
Some that I have encountered have me thinking that a prerequisite for owning & working on one of these little CRD's is to have had your funny bone removed! But then I read a post from you & my faith in human nature is restored.
I hope your cat is fit & well & CV19 is not in your environment.
Here in Australia by shutting the borders the country has avoided much of the destruction. Being an island, I thought you may have been safe.

Most engine re-builders have a separate tank for any parts that have any aluminum in them.
Its a pity that in attempts to save the planet many good solvents have been banned. Chlorinated solvents used to be good for engine work.

I hope your wrist pin bushes solve a lot of the clanking.
Its spring for you guys so lots of progress can be made. Over here we are headed for winter, every time I think of working on mine a cold change happens.
Stay Safe
LB

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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Thu May 07, 2020 3:15 pm 
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Thanks layback40,

I'm glad my jolly spirit refreshes you. Sometimes I think I'm simply insane.

Yes, Hawaii island has been closed. We had 75 positive CV-19 and 70 have been released from hospital, and no deaths.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 13, 2020 11:28 pm 
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Joined: Thu Oct 05, 2017 2:22 am
Posts: 445
Got the block painted yellow again and put the crankshaft back in. From here on out I will be frightfully careful of the oil I put in it. Polished the crankshaft journals, cleaned the crankshaft supports and put new bearings in all 5 crankshaft locations.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Sun Jan 17, 2021 7:00 pm 
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Joined: Thu Oct 05, 2017 2:22 am
Posts: 445
Guess who's back... ME !!!

My poor Jeep has been sitting in the same place and untouched for 7 months. At present I'm waiting for the block to come back from the machinist after aligning the piston-top/wrist-pin lube jets. He's had the block for about a month so far... hmmm...

However, today I've replaced the passenger-side lower front ball joint while leaving a vast void in the wheel well. Trying to remove the first shaft from the differential to the half-shaft, ...removing it from the innermost part of the half shaft.

Image

So far I'm used a ball joint removal wedge with no success. It does slide back & forth about 1/16". Any suggestions out there?

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Sun Jan 17, 2021 10:15 pm 
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Joined: Sat Aug 24, 2013 11:36 pm
Posts: 6209
Location: Central GA
Clamp the half shaft in a good vice good and tight in an area in the middle of the shaft where it is NOT machined, and then rap the back side of the CV joint housing real hard while pulling on the housing.
All that holds the halfshaft in the CV joint housing is a small circlip that is slightly larger than the shaft. The CV housing should slide right off the halfshaft with a few good hard whacks with a big hammer!

Image

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Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Sasquatch BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 bld.fan/NAPAHDClutch
IronrockArms/wwdieselMount


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Mon Jan 18, 2021 12:02 am 
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Thanks WWDiesel,

Thank you, thank you, thank you !!!

That worked in 2 whacks then another couple to drive it off. I was feeling useless -- just needed a nudge over the hump.

Have some new struts coming in from the mainland that should be here by the end of the week.

During the last several months I've been burdened with diabetes, but finally got my diet under control and I'm easing back into life. Little victories like this axle shaft help to regain my confidence.

Thank you for more than you offered. You should smoke a cigar tonight.
Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Mon Jan 18, 2021 1:50 am 
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Joined: Mon Mar 24, 2008 10:26 pm
Posts: 921
Location: West Coast, Canada
Did you fix the solar array? [WINKING FACE]

Sent from my SM-G965W using Tapatalk

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2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Mon Jan 18, 2021 1:58 am 
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CaptainDean wrote:
Thanks WWDiesel,
Thank you, thank you, thank you !!!
That worked in 2 whacks then another couple to drive it off. I was feeling useless -- just needed a nudge over the hump.
Have some new struts coming in from the mainland that should be here by the end of the week.
During the last several months I've been burdened with diabetes, but finally got my diet under control and I'm easing back into life. Little victories like this axle shaft help to regain my confidence.
Thank you for more than you offered. You should smoke a cigar tonight.
Dean.

Great! :BANANA:
Knowledge is for sharing... :wink:

_________________
Supporting Vendor and Moderator of LOST
05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/Shocks
Yeti StgIV Hot Tune
Sasquatch BatteryTray
No FCV/EGR
Samcos/ProVent
SunCoast/Transgo
Carter Intank-pmp
2mic.Sec.Fuel Filter
Flowmaster/NO CAT
V6Airbox/noVH
GM11 bld.fan/NAPAHDClutch
IronrockArms/wwdieselMount


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Mon Jan 18, 2021 2:52 am 
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WolverineFW wrote:
Did you fix the solar array? [WINKING FACE]

Sent from my SM-G965W using Tapatalk

WolverineFW,

Yes, we did fix the solar thermal array. Feb 1 is our drop dead date and we are just going to make it.

We had a problem with the 'sun tracking' software that we finally figured out, as well as all the Automated Logic modules, and the microcontrollers in the solar field, and wiring throughout the plant. Part of the plant (some panels, heat storage tanks, Automated Logic modules, 4" copper plumbing) had been removed.

The Automated Logic modules had sat unpowered for 7 years so replacing all the batteries helped bring them back to life. The 12 one-off micro-controllers that seemed to be built in someone's garage had to be sourced and replaced. The underground wiring had become saturated with ground water and ruined. Our IT guy could not understand that building up a new server and client machines in today's up-to-the-moment Operating Systems would not work with 2008 vintage software on XP. The folks who removed parts of the plant had luckily never used them, so it was easy to transport them back and 'crane them' back into place. The 4" copper piping had to be brazed back together which meant I had to dust off my 50-years-back skills and braze them back together.

On Tuesday I should finally be able to create heat and display a functional (in-work) plant. We had 5 people to help me. 2 were grounds people, 1 is a pump & motor guy, 1 electrician, and 1 superman electrician/coder. As the end drew nearer, I lost 3 people; 2 retired and superman moved up to management.

Looks like we're going to make it. Thanks for all your help on the Air Conditioning forum. You helped me a great deal.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Mon Jan 18, 2021 2:27 pm 
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Joined: Mon Mar 24, 2008 10:26 pm
Posts: 921
Location: West Coast, Canada
Nice work Dean

Glad you got it working, even being hamstrung by your IT guy. Sounds like he finished last in his Comp Sci class.

There are lots of controls tech running around with old windows laptops with serial ports still that they need to use to interface with old obsolete control systems.

Sent from my SM-G965W using Tapatalk

_________________
2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Sun Jan 24, 2021 2:18 am 
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While waiting for the block to come back from the machinist, I'm replacing the front struts, half axles and lower ball joints. Got into a problem with the driver's side half shaft -- it won't slide all the way into the differential. It is engaged because I can move the driveshaft by rotating the half axle. I've tried different angles, attempting to ram the axle in by hand, and even tapping the outer end with a hammer. No joy.
Image

Any suggestions out there? The passenger side half shaft went in perfectly.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Sun Jan 24, 2021 3:46 pm 
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Joined: Mon Mar 24, 2008 10:26 pm
Posts: 921
Location: West Coast, Canada
Are these reman shafts or new straight outta China shafts? Do you still have the old one to compare the spline end to the new one?

Sent from my SM-G965W using Tapatalk

_________________
2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Tue Jan 26, 2021 3:14 am 
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WolferineFW,

I've had these half shafts for a couple years and finally getting around to installing them. I don't remember if they are rebuilds or new Chinese shafts -- they look new though.
Image

In the end I installed the original (used) shaft back into the drivers' side.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Top
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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Tue Jan 26, 2021 12:55 pm 
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Joined: Mon Mar 24, 2008 10:26 pm
Posts: 921
Location: West Coast, Canada
If the old one went back in, I would say there is something off about the splines on the new one.

Sent from my SM-G965W using Tapatalk

_________________
2006 Liberty CRD Limited

Provent @ 43,000 km
SEGR in progress
SAMCO Sport hoses @ 48500 km
Goodyear Wrangler Duratrac LT225/75R16


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Sun Feb 07, 2021 5:18 am 
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Posts: 445
I put the old one back in on the driver's side. The new one must be a Chinese unit. It did connect with the splines because I could drive the input shaft with the axle. Only the unsplined part of the shaft would not go into the bearing.

Talked with the machinist yesterday and he has finally started on aiming the jets on my block. Two were missing the holes in the pistons. He hopes to get it out this week. ...I hope he gets it out this week.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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