FULL FEATURE - Bosch P7100 Rebuild for MINT 5.9L 1995 Dodge Ram x
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- เผยแพร่เมื่อ 2 ต.ค. 2024
- Area Diesel Service Inc has partnered up again with @watchweswork for a rebuild for a rare beast - a mint condition 1995 Dodge 2500 4WD with the famous 5.9L Cummins 12-valve engine. This unicorn has been well-maintained and after Wes was able to do some repairs in his shop, an intermittent issue arose that pointed to an issue with the P7100 Bosch inline pump.
That is where ADS stepped in with our team of diesel experts, and 40-year inline pump expert, Gary Dahler, to investigate the issue and remanufacture the P7100 Bosch pump to better-than-ever status!
ADS experts guide us through the highly-detailed process, a process from start to finish normally takes up to twelve hours + to complete!
Follow along through this full-length meticulous process of assessment, disassembly, external clean up, blasting, internal parts cleanup, diagnosis, parts replacement, reassembly, Bosch test stand test and calibration, final touches and good-as-new review!
Watch Wes Visit our facility in 2021 - • Neglected Forklift Fin...
Any and all costs/pricing mentioned in this video are general assumptions regarding this specific project or projects very close in time, labor, and parts cost for this present time. All our work is priced case-by-case, and we offer quotes to assist in getting our customers the best and most accurate cost for the job.
We appreciate all the feedback and want to pass along that appreciation with a special offer for fans of this content. Do you have a pump or set of injectors in need of repair or rebuild and want to send it to our experts? Get in contact with us and mention our TH-cam channel / Watch Wes Work for some ADS swag and we will cover the shipping - please reach out to us for more details.
To contact Area Diesel Service:
Call: 1-800-637-2658
Email: parts@areadiesel.com
Online: www.areadieselservice.com and utilize our CHAT NOW feature!
Socials:
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Instagram @areadiesel ( / areadiesel )
LinkedIn @Area-Diesel-Service-Inc ( / area-diesel-service-inc )
Twitter @areadieselsvc ( / areadieselsvc )
Watch Area Diesel Service here - / areadieselservice
Watch Wes Work here - / watchweswork
Thanks everyone for their comments and inputs. I’d like to think every job I have done, is to this standard.
Appreciate letting us look over your shoulder.
It was awesome watching a true craftsman at work! Great job Gary!
Gary, you might feel that you have just "done your job", I would like to point out your skills, problem solving and methodical attention to detail are not "run of the mill" and you should be congratulated.
very nice work.
Many thanks for being allowed to watch you work Sir. I got lost after 5 minutes, deft Hammer skills, and sublime hand to eye coordination.
Certainly not a job for any sort of gifted amateur.
Stay safe 🙏
Came for the Wes connection, stayed for the content.
Thank you for the effort it takes to post this, I enjoy the work!
That pump is a complicated beast , thank God for guy's like Gary who understand how they work and can fix them like new !
Gary is clutch. I love how he gets pissed that someone didn’t use factory parts.
Geek level every time I loved watching a professional at work.
Preferred the "deep dive" version. Awesome job on that pump. Gary is one hell of a technician. He's a treasure for the company. Excellent video on what you folks are about.
You sir are a malfunction finding,investigating and answer getting guru, and a genius. Great job finding and investigating the problem. And an amazing explanation of the entire process
Gary knows this work backwards and forwards, nice to see someone who has that "built better in America" attitude that was so common in years past! Great job thats for taking us along!!
These guys are the best!! They fixed my asv injection pump, and helped me with many questions. I will have these guys do ALL my diesel work! Thanks
I was surprised at how much of that classic diesel sound is from the pump. Always thought all that clacking was purely engine related.
Found about you guys from Wes’s channel. Sent you the CAV pump and injector out of my 1958 Lister LD1 over the summer, beyond pleased with the results. Can’t thank you guys enough.
Stumbled on 2days ago an watched cc equip.rotary rebuild.easy to understand nothing but good i've heard over the years.detail understanding and listening to complaints and a clean environment.top mechanics who understand this complicated work.if only the younger generation and some do take jobs seriously.awsome video.Thanks
Gary is a BEAST and a legend! Red shirt dude, excellent use of schmoo, AVE would be proud!
It is awesome to watch a true professional technician do their work. Thank you for bringing us along. I appreciate it. And thanks for slowing down to explain. I am humbled by your knowledge and skill.
Long version - yea! $2000 actually sounds fair for a typical high quality rebuild/overhaul. Yes, $3600 sounds high and is, but me too as a customer would be pleased with no regrets.
I came here from Watch Wes Work.
Bloody fascinating. Thanks for the autopsy and revival!
These pumps are work of art themselves. The amount of pieces and devices to control fuel delivery is amazing! Gary makes it look so easy until we lift the hood and face the reality
Very interesting and informative! Thank you for sharing this process with us
I’m not even a diesel guy and I enjoyed the longer version. Always interesting to get a behind the scenes with a rebuild expert. Makes me think twice before digging into a precision machine I know nothing about.
Nice ending btw.
One outstanding build
Amazing how many complex operations go into the building and calibration of something that on the surface sounds simple...like a fuel pump.
"Fuel Pump", "Injection Pump" two completely different things.
love watching masters at work.came here from www,s channel. sat glued for the entire 3 hours so now i gotta go to bathroom lol.great vid
Wow! Very detailed and put together very well! My only regret is the audio around the calibration stand wasn’t good. That was one of the most interesting parts to me, to see how the timing and fuel delivery was adjusted, but missed out on some of the explanation. Maybe a different audio/mic set up would help ??? Between C&C, Dirt Perfect, and now WES, I finally made it to your channel. I subscribed and look forward to future content! Growing up on my grandfathers farm I learned to work on equipment and trucks, and developed a fascination for mechanics. I still do all my own wrenching but I wouldn’t tear into a diesel pump for nuthin but trouble and a headache. It takes a skilled experienced expert to do “some” jobs and my hat’s off to Gary! I work daily with 480 volt electricity and trust me, you better know wtf your doing! Experienced skill is everything!
Thanks for your comments Sparky. I’ll do diesel, you do electricity
New subscriber thanks to the recommendation of Watch Wes Work. You come highly recommended and I will enjoy watching your channel and videos starting with this one 🇺🇸👍
WWW suggested Viewers watch this channel. Wow! I'm not a diesel guy, had no idea how large and complex a pump was. Reminded a a little Kubota diesel. Great video. Thanks for the content.
Definetly subscribing after coming here from Wes. Great work.
I watched the deep dive. I love watching someone like Gary who totally masters their trade - whatever that trade is. It is often sadly missing from lots of organisations. It is for the same reason I watch Wes. He is really smart at diagnosing his problems but also knows his limitations and uses a specialist like Area Diesel when out of his range of skills. Thanks Gary for letting us look over your shoulder whilst you work.
Very very good video! No back-patting, look what I did type stuff. Take pride in your work, nice job!
Awesome video! Gary is the guru for sure!
Gary tells you how many years he has been working in this field. Just by looking at the work he does . Plus he explains a lot. You can literally see how many years he has without telling you. That is some awesome work you do. .
That is crazy, I'm shocked those o-rings can hold back enough pressure from the expanding grease to cause the barrel to compress!
Sure it took some coin to fix up that P-pump but it takes even more to do a full fuel system on a common rail so....... that is a super rare failure that one of those o-rings let fuel by and was sticking the plunger. That messed up retainer plate cocking the barrel just enough was probably what started it. Should be good for the rest of that engines life now. 🙂
I love the 8.3 Hyster videos.
From the other channel it looked to have a Gale Banks aftermarket intake on it so there’s a good chance some Banks pump mods were done along with that.
i like the long version, thanks
I think I was on meds on the first version.
Very much a pleasure to see a dedicated Craftsman at work.
Especially nowadays- 40 years experience is hard to come by with anything.
I've found this fascinating , such knowledge
Probably the longest video I have watched on TH-cam, and enjoyed every minute of it. Thanks guys.
I’m not a diesel mechanic but if I am ever in need, you can guarantee that I’ll be doing business with your excellent team of professionals. Cheers from Cincinnati, Ohio.
Quality job 👍👍👍
Original parts lasted all those years, why risk it with lesser quality parts? Great video! Came over from Wes' channel. Kudos to @garydahler8291 for the expert repair and great commentary.
I had the same exact issue with my truck was absolutely a stuck plunger. I put atf in my fuel and fixed it. Just barely ground down the high spot by a little with the abrasive in the atf
Great job Wes is going to be very happy, what a great company and the skills the techs have are really something to watch. I thoroughly enjoyed watching the pump being rebuilt, and you really have to know what you are doing I,ll say.
great work guys
Excellent work Gary, your a true craftsman that pays close attention to the fine details. Something critical in diagnosing and identifying the source of the problem in this situation. A real asset to ADS. Thanks very much for sharing.
That pump is ready for a million miles. Awesome work!
I have never watched a video of this length before on Utube, I found this long version fascinating, watching someone with Garys experience . I will certainly subscribe Mike UK
Watch Wes Work sent me to watch this educational video.
Thank you for maiking a long video for us special needs "want to be someday" mechanics
Damnation! That is complicated machine. It's probably more complicated than the engine itself especially in terms of the number of different parts and their interactions.
Almost unbelievable
Like the split video format. Wish more channels did that - top level overview and then the nitty gritty. Great work.
I like both versions. I watched the shorter version first and then this version to see some of the in depth stuff. Thanks!!! 👍👍👍
seeing the torque seal used as paint was fun.
Fascinating
If I remember correctly,
Cummins Australia wouldn’t let anyone fix a p pump let alone supply parts.
Box them up and send them to the other side of the country and hope they didn’t schedule the rebuild for a Friday arvo or a Monday morning.
It was the late seventies and it was Australia 😎👍
There's a modern replacement that's much smaller and bolts up the exaxt same way for the d342
What talent and skill! Almost makes me want to break something just to watch you fix it.
Great video. Learned a lot even though I am not diesel minded. Complicated piece of equipment. Gary knows his stuff. Great ending!!!
great video
I watched the 2:41:21 version of your video loved every minute of it. Thank you for airing it I do watch watch Wes work all the time love his channel I do have several questions one is what do you do with someone send you a Bosch pump similar to this one only all set up for racing like a Banks race pump just pick up at banks equipment on it wondering about that also I have a 1997 Chevrolet 6.5 diesel. Could you do an in depth tear down and rebuild on one of those pumps please. And also what are your thoughts on those pumps the DS 4s
Thank you for taking the time and effort to make this very interesting and informative video. It's a superb demonstration of the work of your company and its dedicated employees.
Another great video you guys have put together. I much prefer the long and extremely detailed version of any technical video. I don't care how many hours it might be, I will watch every detail with great interest. May I suggest a microphone for Gary to wear. I want to hear everything he has to say. Also multiple camera angles so we can see all the fine details. Suggestions for future videos would be checking and setting the governor foot engagement and governor teardown and rebuild for one of these P7100 governors, along with more details while setting the fuel rates on the calibration machine. Thanks so much for putting this together for us to watch and learn.
We have a similar video, on a P 3000 series Bosch. With the same governor. 4 part series. It was for a 8.3 forklift 🧐
Low starved oil could this affect operating conditions as parts over heat sticking? Mystery one
Fantastic experience, dedication & skill. Really enjoyed watching Gary performing his craft on this pump. Thanks for sharing.
I'm guessing I just enjoyed the last 2.6666789 hrs geeking out. It took me over a month to watch this after Wes's video, but glad I finally got the time.
I laughed rather hard at your closing line, borrowed from Wes, who borrowed it from the classic reach-around master Mr. Eric O from @S.M.A🤣🤣👍
I came over from WWW to see what you guys do. I'm very impressed with your very clean shop and Gary's assembly and troubleshooting skills. I worked in manufacturing as an Industrial Engineer estimating and setting production costs on hydraulic product assembly and testing. Very impressed on quality of Bosch product for quality and ease of assembly.
Thanks Milwaukee. As much as I preach Bosch, we do use “after market” plungers in our Caps Kit replacement pumps. Outstanding. I’m sure they had someone like you involved. 😊
Amazing care taken. The pump looks like one of those WWI Mercedes in-line aero engines from the front.
I just went back and checked, turns out i was right. That truck had a banks system on it. That isn't a fly by night company. The products they make are high end and very much on point. I've seen a banks power pack put over 100hp on diesel. He's quite picky about dyno tests (ie. They MUST follow SAE regs. or it isn't a valid test) and he's gotten some serious power out of his shop. So whoever worked on that pump was using high end parts, not that means that the installers (unless it was banks themselves) was any good. Just that those banks parts were tested to an inch of their lives and are very much high quality.
Edit: i just realized that i never said who "he" is, that would be Gale Banks and it was just a cold air induction system that gave the 100 hp increase (actually it was 109 or so)
Absolutely amazing video! I looked up your website and was tickled pink that you have a location in Indianapolis Indiana, just 1.5 hours away from me!
If I ever need help with my 94 p-pump, I'll definitely hit you guys up!
Thanks when I worked at wv in the late 70's early 80's and rebuilt these pumps if the plunger was 1 and 1/2 degree hotter than the barrel the plunger would not fit in the barrel. So I can believe a little grease and oil could compress or more likely the barrel temperature would become cooler than the plunger due to the thermal conductive path formed by the grease.
Your company does excellent work! Love how throughly you guys do things and take care of the customer. This is the way it should be. Cummins P-Pump version is most definitely 'the one to have' if you're into good reliable performance that you can turn up easily and don't have all the emissions/ electronics B.S. Thank you very much for sharing this, I enjoyed it!👍👍🙂
Price sounds fair to me. Amazing process.
Shout out to Area Diesel! I came here from Wes' channel, great to see this collab!
Those old mechanical pumps and really any old complex piece are not very tolerant of messing with. When one thing is changed it leads to a cascade of things that have to be matched to the first change. Most aftermarket hop-up kits won't go that far to get all the steps done. It will run good, for a while.
Came over from Wes’s channel. I don’t understand a lot of the technical talk but I do understand “shmoo”. Good stuff!
I bought my 24 valve pump rebuild from you. I also have a 12 valve with a P pump. If it has any issues when I get it restored, will be sending to you. Would have not known about you without Wes videos.
When I was an apprentice in the 70, part of my training was in the pump room, where we used to refurbish mainly CAV jerk pumps, I really enjoyed it, with a strip down area, and a separate clean room for assembly, then the calibration rig, Gary reminds me of the craftsmen that used to work there.
Awesome technician..awesome video..tell everyone else in the shop to lay off the air tools when the master is at work!
I have one of these on my bus. I thought I was boned with parts for it, but damn, these P pumps were in everything, all over the world! Mine is on a MAN flat 6 diesel (10.35Liter).
This is one great video though
Gary you are a artist. came over from Wes’s channel Great video thanks guys.
Nice to know that there are still Old school machine shops around that have the institutional knowledge to get it right. Why is there always time to do it again, hopefully there will not be a next time..
Pretty sure many petrol/gasoline engine guys are in amazement at what is involved in those old "Oil Burners", partly the reason these engines cost more.
Excellent insight into the heart of a Rudolph Diesel engine.
Love that bench swivel manipulater, par excellence all.
Thanks for sharing, and many thanks to all .
Best regards from the UK.
John.
Excellent.
Much better than the Cummins tutorial when I did my apprenticeship 😎👍🍺
Dude is amazingly good at those rebuilds. WOW, I'm amazed.
That’s what it’s all about doing it correctly, and experience. Thanks.
What a beautiful craft , thanks for sharing 👍🏼👍🏼👍🏼👍🏼👍🏼
Thank you for great video. The technician is a real professional. Question: Wouldn't your shop's test stand have been used to operate these pumps in advance to a teardown to not only attempt to duplicate the condition, but to measure pressures from each of the 6 outputs? Then after rebuild you retest and confirm to specs and show improvements?
Thanks.
I don’t like adding time, and labor to a job. No matter how long it takes me to duplicate the situation, I would still have to rebuild the pump, to guarantee it 😮
Garys a master of his craft great job would def send u guys my pump if needed
Really enjoyed the video. Thanks for taking time to document and present it!
I like both formats, The short one for quick info, the long one for detailed info. Nice job, proffesional done.
I enjoyed the video where Wes was visiting your location, liked and subscribed now!
Your expertise is beyond reproach. Great work.
American Quality Workmen = 100% QUALITY Guaranteed !!! Area Diesel Service must be so proud of its business practice and quality workmanship. Thanks to Wes for introducing A.D.S. to the entire country. Oh yeah, Gary you the man!!
"Area Diesel Service" NOT "American Diesel".
Great Video. You guys really know your stuff. It's great to watch experts work. But didn't you say you would level the top face of the pump too?
I only wish, the sound was better. Like using a lav mic or so. As a non native speaker, I sometimes have a hard time understanding when the environment is noisy, but I could follow quite well.
Oh, and of course I camer from www and the unicorn. ;)
Thanks for the feedback, we are hoping to eventually upgrade the audio capture.
Watch Wes sent me here! If he says you're good you must be!!! Lol
Great content! A lot of good information for us diesel owners. It was a pleasure watching Gary work.
I rebuilt 7.3 injectors myself...thats the end of the road I see. This was insane
That pump is insane. Wow, that's some serious engineering. It's far more complicated than the 12 valve it's typically mounted to.
Gary is a awesome teacher. Very hard to find or keep someone like him. God bless
Long version was very educational, thank you
Great video and I learned a lot. One question I have and maybe someone else asked it but could you run the pump on a test stand before you tear it apart to see if you could replicate the problem. Maybe add heat to the housing to simulate higher ambient temps or excessive operating temps while monitoring fuel flow? Just curious if that is even an option. Again, you guys seem to do a complete and thorough job on your rebuilds and I really enjoy learning from people that know their business.
I don’t like adding time and labor to a job. No matter how long it takes to duplicate the failure, I would still have to rebuild the pump, to guarantee it. 😮
Just wanted to say thank you for the extremely detailed video. Well my 2002 bus with a 5.9/24v/vp44, is now complete. I will be dropping you an email soon about what should be done to ensure reliability, and a bit more power. Nothing is currently wrong, but the unknown blank tag on the VP44 saying "rebuilt" with no other info bothers me. Chat soon.
John A
60107 Illinois.
Stock pump, stock parts stock settings. Dodge detuned these from Cummins specs because of the Transmission…. 🤦♂️🤦♂️🤦♂️🤦♂️