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Old 09-09-2017, 07:44 PM   #1
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Pulling the 5.9 with the at 545 still bolted on

The engine and transmission only have to move fowar a few inches and canbe lowered right in to your dolly underneath. Going to strap the at 545 to a harbor freigt trans jack and use a cerrpickr to lift the 5.9 at its cg
Here are some pictures next weekend we will pull it out
Hmm pictures in a bit
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Old 09-09-2017, 07:59 PM   #2
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is your 5.9 defunct? or are you doing a power-plant swap?
-Christopher
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Old 09-09-2017, 09:28 PM   #3
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Hi Christopher

Bad oil leak from the lifter cover which is behind the Bosch pump the air compressor and the power steering pump. The frame rails are right there also it is just easier to pull the engine instead of fighting it. I received the overhauled 545 today and moved it into the shop.
My plan is to go through all seals front and rear oem replacement for water pump, thermostat, new idler bearings, belts,rebuild the starter with HD parts and a new alternator. Am also going to replace both a/c compressors.
Hoses, all new SS clamps and a shop rebuild of the turbo filters and fluids and down the road hopefully by Christmas.
Also, when I took off the gear cover today, the killer dowel pin had not been repaired and i it was poking out an eigth of an inch!!!
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Old 09-10-2017, 03:23 AM   #4
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Also, when I took off the gear cover today, the killer dowel pin had not been repaired and i it was poking out an eigth of an inch!!!
KDP

Engine will be much easier to work on once out. It's a bit tight in there, no?

Looking forward to pics. How high did you have to lift the bus to slide engine out?
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Old 09-10-2017, 08:05 AM   #5
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is this an FE bus?

with all you are doing deinitely makes sense to go ahead and pull the engine rather than mess with the frame rail clearance issues.. I didnt realize you had the dreaded tappet cover leak. id KDP a big issues? I realize in your case it sounds like yours was on the way to falling out but did it affect many engines? or is it just luck of the draw whether that pin drops safely away from the gears vs going through and doing damage?

a friend of mine wants a bus .. and swears by the 5.9, he is looking at short conventionals.. I think he has been looking at 00+. which shouldnt have the KDP issues?

-Christopher
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Old 09-10-2017, 10:20 AM   #6
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The dreaded KDP

My understanding is that it is only an issue in the 12v engines. As for how High did the bus have to be lifted to get the engine out it is currently on HF 12 ton jackstands with the front tires a couple of inches off the ground for disconnecting everything. I probably will set it back on the tires to pull it. The front engine support rests on a steel frame rail that has 3 bolts on each side; when removed it is a straight pull out. I have pictures on my phone but forgot said phone at the hangar.
This is a 1991 Bluebird 28 foot Handy bus front engine 5.9 and a AT 545.
Attached Images
File Type: jpg engine front view.jpg (73.9 KB, 16 views)
File Type: jpg bus front teardown.jpg (152.0 KB, 16 views)
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Old 09-10-2017, 02:58 PM   #7
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Pictures 5.9 fe bluebird

1000 words. Etcb
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File Type: jpg 20170910_105126.jpg (69.3 KB, 13 views)
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File Type: jpg 20170907_111835.jpg (157.5 KB, 15 views)
File Type: jpg 20170909_114112.jpg (167.5 KB, 14 views)
File Type: jpg 20170827_150048.jpg (145.2 KB, 18 views)
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Old 09-10-2017, 03:01 PM   #8
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1000 words. Etcb

Thanks for photos- is a big job. Engine looks so clean.
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Old 09-10-2017, 04:39 PM   #9
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wow!! thats stuffed in there!.. so theoretically you can lower the front of the engine down with the cross member still attached then roll forward? what do you use the cherry picker for?

also i can say that yes the Harbor freight trans jack will hold and articulate a 545.. I used that jeck to do my 545 to 1000 swap.. the bolts on the little hold arms though did slightly indent the pan on the 545.. try to leave the converter and adapter ring with the transmission.. with the trans tilted neutral or slightly back the converter wont go anywhere. and you'll want the jack as far forward as you can get it on the pan.. as the transmission is definitely front heavy.. the jack wheels are small and I used a tire iron as a lever against the floor to help move my trans.. my surface was asphalt and a bit rough to roll on.. you have a nice smooth garage floor so hopefully no isses there.

-Christopher
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Old 09-10-2017, 08:22 PM   #10
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545 continued

The engine is supported with a chain front to rear in the existing
chain loops bolted to the engine. The HF transmission jack has a piece
of plywood with carpet that will be strapped to the AT 545. I upgraded
the wheels on that jack the first time it was used.
Then to unbolt the bellhousing ears and lift the engine/ trans up with
the cherry picker and the HF jack enough to roll it forward a few
inches.
Finally, remove the front engine mount support bar and lower it into a
wood cradle equipped with 4 inch steel wheels and roll it out and away
The cradle is built out of 2x6 and 2x10s and bolted together with 3
5/8 inch structural fasteners.
Pictures coming on that one still waiting for the wheels to start building it.
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