...
DO
DoWwDodge Power Wagon M880 W200
Full Gasket Set, Mopar LA / Engine Rebuild Kit Dodge Power Wagon M880 W200
...
DO
DoWwDodge
Power Wagon M880 W200
Full
Gasket Set, Mopar LA / Engine Rebuild Kit Dodge Power Wagon M880
W200
Full
Gasket Set, Mopar LA / Engine Rebuild Kit Dodge Power Wagon M880
W200
Before you start to rebuild
your Dodge Power Wagon M880 W200 Engine it's a good idea to invest in a
full gasket set, for example FEL-KS2108. These Fel-Pro gasket kit sets
include premium-quality head gaskets, intake gaskets, exhaust gaskets,
valve-cover gaskets, oil-pan gaskets, valve-stem seals and all accessory
gaskets, everything you need for a complete engine rebuild, all in one
affordable set. Or in an even more extensive set for example a combination
of Sealed Power and Fel-Pro parts, dependable if you want larger pistons
you can choose the set by search for "Engine Rebuild Kit" and your engine
size, then order it with your personal wanted specifications. above
...
Cylinder
Compression Check Dodge Power Wagon M880 W200
The compression check was
so bad that we doubt about the compression gauge, so we take a look in
the manual from "Haynes", no increasing pressure within 4 strokes could
mean bad heads and good piston rings, second test: pour a couple of teaspoons
of engine oil into each cylinder and check again,the result was still the
same and no increasing pressure, according to Haynes, the piston
rings should be okay and the valve or the heads leaking, so time to take
a look into the engine, I already had in mind to replace a lot of engine
parts, eventually we replaced almost everything. above
New
Heads / Removing the old Heads Dodge Power Wagon M880 W200 
Well the old heads looked
like funnels, when we poored spirit into the ports, the valves were
not leaking, it just stream out like little brooks!! So if it was that
bad, then New Heads from Edelbrock: EDL-60779 (order 2, most shops don
not sell them as a pair), Bolt-on power, right out of the box.
These aluminum cylinder
heads feature threaded inserts in the rocker studs and exhaust manifold
bolt holes for superior strength and durability, plus hardened seats, bronze
valve guides, and fully machined valve cover rails for a more consistent
gasket seal. They offer improved power throughout the rpm range for greater
throttle response and top-end horsepower. The intake and exhaust runners
are CNC-machine profiled for superior flow and performance. These Performer
RPM heads are fully assembled with stainless steel intake and exhaust valves
with undercut stems, 2-ring positive oil control seals, rocker studs, hardened
steel guideplates, valve springs, retainers, and keepers.
Notes: Dodge Power Wagon M880 W200
New
Camshaft Dodge Power Wagon M880 W200 1976 military version 
I have choosen for a new
camshaft from Crane Cam, it boosts the low-end torque and horsepower, the
new lifters are included in the package, read the instruction included
in the package for installation and lubrication (Summit: Crane Truck Power
Cam and Lifter set, partnumber, CRN-693904). above
Rockers
and Rockershafts Dodge Power Wagon M880 W200 1976 military version
The shafts looked still
good, at first side, but when you look more carefully they were excessively
worn, there was so much clearance that the whole assembly looked like an
abacus, we could move the rockers about 3/16 inch to the left and right,
because when you buy new Edelbrock heads you have to use a set of adjustable
rockers/shafts and spacers (according to Edelbrock), if you click on the
partnumer at Summit, so in this case the heads (EDL-60779) and then click
on suggested parts you can find the other parts which are necessary. above
New
Shaft Mount Roller Rockers and Spacers Dodge Power Wagon M880 W200 1976
military version
There are just a few different
brands that make these, for example Crane Cam and Harland Sharp, I have
choosen Harland Sharp because the time of delivery was shorter (CSP-S70025K
(1.5)), you can also choose for the 1.6 ratio, but then there is a chance
that the lift of your valves will become too high and the risk that your
engine will be damaged is becoming bigger, this may be interesting when
you are a professional off-roader and disamble your engine every day, besides
that you can with the 1.5 set also adjust the lift of your valves, so still
pretty wild, the shafts have mount roller rockers, have features like a
needle-bearing, full-roller fulcrum assembly and a roller tip to reduce
friction and wear, and to stabilize valve timing, to mount the set is not
such a problem, the problem is that there is no installation instruction
in the package of this Harland Sharp set, another problem is that
there is not enough information on the site of Harland Sharp, maybe after
all it was better to wait for the Crane Cam set of adjustable rockers/arms/spacers,
because Crane Cam has an unique technical support about this subject on
their side, so you can read everything about how to install this adjustable
rockers/arms/spacers set, you can dowload an instruction manual from their
site, read it several times before you start, you can gain 25 hp, when
I write this I realized it is a good idea to read all the other subjects
from Crane Cam (Cam Shaft and Lifters, Timing Chain etcetera), because
they are really detailed (www.cranecams.com).
...
...
-Tip:
How
to install (short version)? Dodge Power Wagon M880 W200 1976 military version
The new pushrods must of
course be placed in your new intake manifold before you start with the
rockers arms shaft set installation, every piston must be placed (one by
one) in the top dead center, the adjustable screw with internal hex should
be fastened so that your pushrod cannot be twisted anymore by hand, then
the adjustable screw should be turned back 1 to 2 turns, then you fasten
it with the lock nut (if you fasten the lock nut be aware that the adjustable
screw does not move), if you fasten the lock nut with a wrench you can
keep the adjustable screw steady with the help of a hex socket, you do
all the pistons this way, one by one: two turns back means a safe lift,
1 turn back means a wilder result. above
New Pushrods Dodge Power Wagon M880 W200 1976 military version
With your new adjustable rockers it is necessary to measure your needed pushrods carefully, I have choosen a set of Crane Cam, they fit perfectly (Summit: partnumber CRN-69691-16). above
New
"Raised" Valve Covers Dodge Power Wagon M880 W200 1976 military version
Tips: Dodge Power Wagon M880 W200 1976 military version
New
Aluminum Intake Manifold Dodge Power Wagon M880 W200 1976 military version
I have choosen for the
Dual Plane Spread Bore Edelbrock: EDL-2176, there are more different brands
who supply this (for example Weiand (Holley), but as for design and output
there is not much difference, you can order the Edelbrock intake manifold
polished or chromium (for the enthousiastic)
Problems Dodge Power
Wagon M880 W200 1976 military version
Edelbrock recommends that
you should not use the two cork gaskets (back and front), that are included
whith the intake manifold gasket set (FPP-1213) and instead of that use
a lot of sealer, my experience is that that does not work at all because
the space between the intake manifold and the headers is at least 3/16
to 4/16 inch, you cannot seal this with the fluid seal, I tried to do this,
but the result was terrible, the fluid seal even did not come out between
the two surfaces, when I removed the intake manifold you could very clearly
see that the sealer did not reach the surface of the parts at all, also
there is no control about how the sealer touches the distributor shaft
later (and how to cut this away with a knife: into your block), it was
also very difficult, almost impossible to screw the intake manifold bolts
into the heads, let alone to fasten the bolts, after we removed and cleaned
the intake manifold we have elongated and oversized the holes a little
bit, before that we have marked the bolts that gave problems and we could
mark in which direction the holes had to be elongated, the assemblage with
the cork gaskets and a thin layer of sealer went perfectly, make sure you
have the right size of hex socket with a extension in combination with
a U-joint of the smallest size.
Tips and small necessary parts: Dodge Power Wagon M880 W200 1976 military version
...
...
New
Harmonic Balancer Dodge Power Wagon M880 W200 1976 military version
I have also replaced the
balancer, because the rubber was rather worn, there are not a lot of options,
so I order the High Performance Internal Balancer (SUM-B64277) at Summit,
it was rather expensive, 260 dollar, very handy is the installation tool
(SUM-G1023), it avoids a lot of irritation, the disassemble (read: torture)
was not simple, I had to cut three holes in the old balancer and just pulled
it out with a universal puller, with the use of the installation tool it
is quite simple to mount the balancer, there is a good installation instruction
enclosed in the package. above
...
...
New
Timing Chain Dodge Power Wagon M880 W200
It was to be expected that
after 30 years of hard work and an advanced ignition of about 14 degrees,
to keep the engine running, the timing chain should be replaced, it was
badly worn, I almost could take the chain off without removing the gears,
I choose for one of the best in quality: Crane Cam: CRN-69993-1, at Summit,
Double roller, iron sprockets, the wrong timing chain arrived in the wrong
box, Summit had a real good service, I send them an email and three 3 days
later they returned the money by Creditcard, in the mean time I ordered
a new one, Summit sent the correct chain by express and did not charge
any freight costs, that was really good news. above
...
New High Volume Oilpump Dodge Power Wagon M880 W200 The Melling high-volume oil pump gives you an additional 20 to 25 percent of much-needed oil volume for your performance application, the pump is built using a proprietary casting process, which yields maximum performance and reliability (Summit: MEL- M72HV(49 dollar)). above
New
High Performance Fuel Pump Dodge Power Wagon M880 W200
Most of the time we drive on propane (which is
common in the Netherlands and is about 30% of the price of fuel), when
go on a holiday, for example to France (or somewhere else in Europe), it
is convenient to have fuel and also a good fuel pump, for a non-hesitating
fuel pump I have choosen at the Summit site for the Holley (HLY-12-838).
Note: The new bolts included in the package are too short, be aware of that, so buy longer bolts or use your old ones.
New
Waterpump, Viscousfan and Alternator Dodge Power Wagon M880 W200 1976 military
version
For more information about
the Waterpump click Extra
Cooling
For more information about
the Viscousfan click Extra
Cooling
For more information about
the Alternator click Electrical
systems
above
How
to repair a worn thread? Dodge Power Wagon M880 W200 1976 military version
What do you do when you
screw a new bolt into your engine block to (for example) mount your waterpump
(with the right torque) and you turn loose? You can use a longer bolt (first
measure), sometimes you succeed, but it is also possible that the previous
owner(s) have not used a torque wrench and therefor were not able to torque
them right, especially material like aluminum (for example the waterpump
mounted to the timing cover) is a weak point when you fasten the bolts,
the solution is the "helicoil" invention.
...
...
It is necessary to order some essential other parts with your carburetor, lots of torque is important when you drive a Dodge M880 truck so it is a good idea to place a spacer between your intake manifold and your carburetor, this 2" spacer allows you to space your carburetor above the intake flange to increase plenum area for more torque and horsepower, it is just what you need to insulate or tune your carburetor/manifold powerband and it does not conduct heat so your carb stays cool for optimum performance, and the spiral bore increases the velocity of the air/fuel charge to enhance fuel atomization, the result? more torque and horsepower throughout the entire RPM band and improved performance, drivability, throttle response and fuel economy (Summit: EDL-8713), you also need a second gasket (MRG-55, Carburetor Mounting Gasket, Nitrile Rubber Composite, 4-Barrel, Square Bore, 4-Hole).
Mounting order: intake manifold, open gasket included with the carburetor, the 2" spacer (EDL-8713) and the 4 hole gasket (MRG-55), carburetor.
...
above
Other
absolute necessary things: Dodge Power Wagon M880 W200 1976 military version
A dual fuel feed line (EDL-8133),
new vacuum hoses at your local store, a Throttle Lever Kit Chrysler (EDL-1481),
without this part it is impossible to connect your carburetor to the transmission
throttle rod and the accelerator throttle rod, the (Auto Transmission Rod
Extension Kit for 5/16” Rod EDL-8004), you have to make a new bracket to
raise your accelerator rod, I copied this bracket from the stock one, using
a new piece of metal and machined it so that it was 2/5 " higher than stock
(do not forget the extra lift of the 3" bodylift), also very handy is the
EDL-8005, Throttle Return Spring, Universal Kit and the SUM-G1320, Dual
Carburator Return Spring, if you want a Manual Choke use the universal
of Summit (SUM-G1300).
...
...
...
Installation: Dodge Power Wagon M880 W200 1976 military version
In the installation instruction of the carburetor is described, step by step, how to connect the vacuum hoses, to my opinion other things in the installation instruction described are not clear, for example, what to do with the PVC breather and the open hole in your other valve cover, I figured it out, not by Edelbrock, but by Summit. Go back to breathers/raised valve coversTips:
Use stainless steel hose clamps for all your vacuum hoses, in the past you could put the hoses to the nipples without clamps, but with the hugh amount of horse power the vacuum hoses will be blown away, my webmaster pointed this out to me when we first started the engine at night and we did not succeed, after this experience, this will never happen to me again. Use a new fuel resistant hose (there should be printed on the hose that it is suitable for fuel) of about 5/16 inside, directly from your fuel tank to your new high performance fuel pump, you will have to remove your old fuel lines. above
Ignition
timing and adjustments Dodge Power Wagon M880 W200 1976 military version
First condition for a comfortable
drive is that your parts concerning your ignition are in good condition
(distributor, coil, wiring, alternator etcetera), second: whether it is
a truck with old parts or with brand new parts, it will not start or drive
properly when the ignition timing is not correct, so in the situation that
you have an old truck with a worn timing chain the advanced timing could
be around 10 to 12 degree (Before Top Dead Center= BTDC) for the best result,
so the only way to examine this, is to do it your self, so do not go to
the garage because they will adjust your timing to the original specification
of the (military) manual, 2 to 4 degrees advanced and your car will drive
worse than ever, my truck drove on propane (which is very common in the
Netherlands) and had the best results around 13/14 degrees advanced ignition,
for driving on fuel this should be around 10 degrees.
I noticed that the Dodge before the rebuild had more torque on propane (somewhere around the 12 to 16 degrees advanced ignition) but how do you read this on the old balancer, you cannot see the mark any more on the balancer, with so much advanced timing.
Solution
Simple turn your balancer/pulley
till you see the old mark/groove, then you make a new mark or groove to
the right about 2 inches away from the old mark, now you have a new benchmark,
you park your truck against, for example, a few blocks of heavy concrete,
a big piece of a tree, you name it, the idea is to have the gear in drive
and when you accelerate the truck should not go over the obstacles, be
sure that the obstacles will not move otherwise, search an other place
to do this trick, then loosen your distributor in a way that you just can
turn it with some force, put the gear in drive in your cabin, then open
your hood and you can accelerate with the accelerator lever by hand, now
you can feel the force of pulling, if you turn the distributor a little
bit and pull the lever again, you will notice a difference in the force
of pulling, you can feel this but also you can hear this, loops while idling
or idles erratically, misses at idle or even engine stalls, if the situation
becomes worse then turn the distributor to the original position and move
it to the other site, remember: just little by little.
You have to do this over and over again, but at a certain moment you have a position were you think of: this gives the greatest pulling, but you are not ready yet, because at this moment your mixture is maybe too rich and your fuel consumption might be not economical, if you now take a look at your new benchmark you can see to which notch on the timing cover it points, in most cases you will not see the original mark any more but just write it down so this could be 8 degrees (opposite your new benchmark), which is not the real measurement, maybe you think what is the reason, why do we have to do this, the reason is you have a new benchmark which you can see, fasten the distributor, then drive the truck again, immediately you will feel the difference but when you are driving on the highway you might notice that it is not running perfectly, no problem you have a new benchmark and at the same way you drive it again and park to the obsticals, slacken the bolt of your distributor again, check your timing again, maybe it points to 8 degrees (opposite your new benchmark), actually this could be 13 degrees or even more, forget this "actually", just turn the distributor until you reached 8.5 BTDC, (which then could be actually 13.5 degrees), again fasten the distributor (take care that it doesn't move when fasten it) and do a new roadtest, you can do this over and over again, so when the result is better you can try 9 degrees BTDC or when the roadtest is worse turn to the other side, this seems to be a boring amateurish story but when it finally drives as you expected, you are glad that you did all this work. You even understand the sound of your truck much better when you accelerate by hand, also you can hear other sounds and feel other vibrations of your truck much better.
After the rebuild, with a new timing chain and a new balancer it's much more easy to check the timing, the balancer has no single groove but a scale from 60 degrees "After TDC" until 60 degrees "BeforeTDC"
Tips:
Dodge
Power Wagon Dodge M880 Dodge W200 1976 Ram Military truck video and pictures