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sailchessi · 06-23-2020, 11:30 PM

A little video and pics of the joys of the new ownership of a well-used coach that needed some repairs. This stuff is not for the faint of heart, but I expected it when I bought it.

Today was the big day, I picked up my “new” (to me) ’03 DS and it is running properly for the first time since I’ve owned it. I had a local independent shop replace the two part exhaust manifold, turbo and Pacbrake exhaust kit. I bought the coach sight unseen at Christmas from the original owner who told me “it needed turbo work.”

Normally, I do much of my own wrenching, but I wanted no part of these exhaust studs rusted away with over 150,000 miles on them. Sure enough, they ALL snapped off and had to be drilled out so I have all new studs too (added to the bill). Glad I didn’t try it, would have faced that without the right tools outdoors. Initial estimate was ten grand. When I took it in, we’d negotiated to eight grand. I had pre-paid $2500 when parts were on order so I could take it home for inside work. Today I paid the balance of the $8,850 total

The shop did a great job but the first turbo was the wrong one and the first Pacbrake kit was wrong and then the right kit came but the actuator/valve was backordered and Cummins is shut down so the whole thing ultimately DID get torn apart and then there was a lot of extra overnight shipping expenses and it was a week late getting it back. They were troopers but this points out that when you have a 2003 coach delivered in May, it has a 2002 engine from Cummins and these companies change the exact parts regularly so there is a lot of opportunity for the wrong stuff.

I waited weeks for backordered parts and then took it back and then was delayed even more. Nobody’s real fault, just these things happen.
I drove it around town, then on I-70 and what a difference. I can accelerate and merge at speed and can “mostly” maintain speed up Interstate grades (within reason). Tried ten miles at 68, then a few bursts over 70 just to check it out, then another long run at 65. Drove on some country roads, tested the new exhaust brake, all really good.

We depart Friday for our first trip as RV’ers and we are just going for it. Baltimore to Austin and back in about a month for probably 3300 miles or so, assuming we make it.

Skip426 · 06-24-2020, 05:37 PM

JMHO: even though that is a braided pressure hose on the Pac Brake actuator ; get it away from the exhaust pipe.

jacwjames · 06-24-2020, 05:48 PM

Yup, I've used the term "Not for the faint of heart" when refer to owning a DP many times.

I changed my own exhaust manifold back ~4 years ago myself. Cost was ~$650. No issues with studs breaking, I presoaked with PB Blaster overnight. Turbo was fine but it was a pain in the butt getting everything aligned doing it by myself.

John Jones · 06-26-2020, 06:50 PM

I did mine a few years ago. Soaked everything with PB overnight and luckily they came out fairly easy. It was a tough job, and I am glad that it is all done.