Heavy Duty Engine Overhaul Kit - 2001-2005 GM 6.6L Duramax 2500-3500
Part # 789-1011
We've had so many calls for a full overhaul set that we had to put together these kits. MAHLE name brand kits include size options for Pistons & Rings, Rod Bearings, and Main Bearings. Kits will typically come in multiple packages and are drop-shipped direct from the MAHLE manufacturing facility.
Kit information:
Pistons
224-3451 (Left Bank) & 224-3452 (Right Bank) Skirt Non-Coated, Use Ring # 41909
OE Part #'s: GM 97226117 (Old Left #), 97303756 (New Left #), 97226116 (Old Right #), 97303755 (New Right #)
Bore (Ø) - 103.0 mm
Compression Ring Groove 1 - 2.0 mm
(Comp. Ring Groove Wi) - 3.0 mm
Oil Ring Groove Width 1 - 3.0 mm
Pin O.D. (BoØ) - 34.5 mm / 1.358 in
Material - Aluminium
Combustion Chamber Depth (MT) - 0.598 in
Recess Volume - 38.06
Casting Number - 103V12
Note - Keystone top ring. Gallery cooled ring insert
Piston Skirt Clearance - 0.002 in
Piston Ring Set
41909 R7 Engine Set, Facing UCR-Plasma-Moly; OCR-Gas Nitride
Bore (Ø) - 103.0 mm / 4.055 in
Thickness - 0.1779 in / 0.087 in / 0.0 in
Width - 0.1181 in / 0.1177 in / 0.085 in / 0.07834 in / 0.0011 in / .0007 in
Connecting Rod Bearing Pairs
CB-1805P
OE Part #'s: GM 97250338, 97250410
Material - TM-77
Housing bore (min - max) - 2.637 in - 2.638 in / 66.985 mm - 67.0 mm
Max. Length - 0.934 in / 23.724 mm
Vert. Oil Clearance (min - max) - 0.001 in - 0.003 in / 0.025 mm - 0.086 mm
Shaft diameter (min - max) - 2.476 in - 2.477 in / 62.901 mm - 62.921 mm
Wall Thickness (max) - 0.08 in / 2.019 mm
Size - Standard
Camshaft Bearing Set
SH-1999S
OE Part #'s: GM 8972182100, 8972182110, 97239516, 97239518
Material - B1 / AL-3
Size - Standard
Part Number's: IS777E, SH-1999, SH-2006
Main Bearing Set
MS-2218P
OE Part #'s: GM 97250336, 97250411, 97250412, 97386937, 97386926, 97386927
Material - TM-77
Size - Standard
Part Number's: CTNC136R-A, MB-3776P, MB3776PAL, MB3776PAU
Thrust Washer Set
TW-610S
OE Part #'s: GM 97219325, 97219327, ISUZU/KOMATSU 8-97219-325-0, 8-97219-327-0, 8 97219 327 0, 8 97219 325 0
Housing bore (min - max) - 106.749 mm - 106.998 mm
Max. Length - 3.0 mm
Shaft diameter (min - max) - 3.504 in / 89.248 mm
Part Number's: CTNC109R-A, MB-3776W, TW610S, TW610SA
Engine Upper Gasket Set
HS54580 (LB7 Vin 1) or HS54580A (LLY Vin 2)
OE Part #'s: GM 97729798, 98403365, 98434773
Item Grade - OEM Standard
Additional Package Contents - Contains Miscellaneous Gaskets And Seals
Torque to Yield - Yes
Exhaust Manifold Gasket Material - Multi-Layered Steel
Intake Manifold Gasket Material - Molded Rubber
Engine Cylinder Head Gasket
54585, 54584, 54583, 54582, 54581, 54580 Final part # pairs depend upon thickness chosen (54580 & 54583 for .95MM (Grade A) thickness) (54581 & 54584 for 1.00MM (Grade B) thickness) (54582 & 54585 for 1.05MM (Grade C) thickness).
OE Part #'s: GM 97333727, 97378104, 98030633, 98045060, 97378103, 97389257, 98030632, 98045059, 97309562, 97378102, 98030631, 980306317, 98045058, 97309559, 98030628, 98045055, 97309560, 98030629, 98045056, 97309561, 97333724, 98030630, 98045057
Item Grade - OEM Standard
Additional Package Contents - Head Gasket
Torque to Yield - yes
Material - Multi-Layered Steel
Cylinder Head Gasket Material - Multi-Layered Steel
Lower Engine Gasket Set
CS54580
OE Part #'s: GM 97729796
Water Pump Gasket Included - Yes
Items in Package - 19
Item Grade - OEM Standard
Additional Package Contents - Contains Miscellaneous Gaskets And Seals
Water Outlet Gasket Included - No
Oil Pan Gasket Material - RTV
Timing Cover Gaskets/Seal Included - Yes
Rear Main Seal Material - Rubber
Rear Main Seal Included - Yes
Oil Pan Gasket Included - Yes
Head Fasteners Included - No
Fuel Pump Gasket Included - No
Reference Info for Duramax Engines:
Left and Right bank head gaskets are NOT interchangeable. Thickness is also not always the same from left to right bank. You can refer to your old head gaskets to get an idea of what you should need for thickness but should measure piston projection when making a final choice. The chart above shows what the stamps and punch holes on your gaskets mean and are as follows:
- 1 - .95mm (Grade A) Thickness
- 2 - 1.00mm (Grade B) Thickness
- 3 - 1.05mm (Grade C) Thickness
- 4 - Block Over-Bored
- 5 - Block Over-Bored & Deck Milled
- 6 - Right Bank (Should also be punched with an "R" but not always)
- 7 - Left Bank (Should also be punched with an "L" but not always)
If old gasket shows (4) Block Over-Bored, 1.05mm (Grade C) thickness gasket is typically used. If old gasket is marked (5) Block Over-Bored & Deck Milled or piston projection measures over 0.376mm you should contact us before ordering.
Duramax engines often have overlapping model years so it's a good idea to check your VIN # to verify which you have before ordering parts!
