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Old 04-20-2019, 10:29 AM   #21
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i would not pay over 7-9k to overhaul an old diesel when you can get more modern remaned engines for under 15k.

When my Perkins needs it i'll go Cummins. It's sad and wasteful but the support dwindles and I wouldn't want to invest in a dying platform.
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Old 04-20-2019, 10:46 AM   #22
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We looked at re-powering instead of rebuilding. When we looked at the running gear, engine beds, shaft log, electrical panel, fuel system, etc., that would have to be changed or modified, the project costs more than tripled. We couldn’t justify it in a 30 plus year old boat.
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Old 04-22-2019, 02:46 PM   #23
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How many hours are on the engine/s?

I rebuild will probably cost you as stated (10-17k). But that’s just the start of it. You would add on 3k for unspecified expenses (getting trannies redone/exhaust, motor mounts etc...)

I have a Lehman with 5800 hours. I put 3000 of those hours on in just 4 years. I do all required maintenance (even lash the valves) and spend the cash on the consumables like elbows/coolers etc.... I ran it at full throttle for about 2400 of those hours traveling. (It’s in a smaller 26foot downeast boat with a 2 to 1 reduction)

I am a worry wart by nature and, like you, figured my purchase of the boat with a rebuild cost. That damn engine just runs and runs. I think it even runs better now, than when I bought it.

My point is, sure, calculate the rebuild costs, but don’t dwell on it. That engine will disappoint you in regards to any plans to rebuild it.
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Old 04-22-2019, 05:17 PM   #24
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I had the number six cylinder in my port FL 120 suddenly develop a severe piston slap in 1987, about six months after I bought the boat.

I had recently reengineered the original muffler system from an all metal muffler place OVER THE TOP of the engine to a fiberglass lift system, but it was not soon enough.

The interior exhast pipe extended upward into the larger diameter "can" of the muffler to near its flat top. Water was injected into the can about midway up its side. Judging by the rust stains dribbling down the sides of the cylinder, the exhaust pipe had long ago rotted out inside the can allowing water to ingress the last cylinder after engine shutdown.

The most interesting fact was that the piston showed signs or "knurling" which is the shady practice of cross-hatching the skirts of the piston followed by smoothing to raise the overall surface back to original or higher. So somebody had previously removed this engine and had taken a shortcut.

For $6500, the engine was rebored, new larger diameter pistons installed along with new bearings, and four hours after getting underway from the FL dealer there in San Diego, the noise returned. The dealer identified the cause as "Bad" pistons and redid the job at his cost. Engine is still running like a champ in 2018 under the new-since-2015 owner.
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Old 04-22-2019, 08:57 PM   #25
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We have twin 4 cylinder Lehmans in our 34' clipper. Found the dreaded coolent in the oil and we traced it to a failed liner.
To be honest any marine diesel mechanic locally was useless for this vintage, so we easily removed the engine ourself and sought assistance from a tractor repair shop. These guys knew the ford engine inside out, completed a full rebuild cheaply and sourced all the needed parts.

we just separated the cooling system and have sourced / serviced elsewhere.

I was keen to perform myself, and understood the theory with the engine being sio simple but didnt trust my practical skills and did not want to go to the trouble of refitting the engine only to find issues caused by my poor workshop skills..

Worth noting we are in Western Australia, so if you are in the US, likely you have skilled mechanics at your disposal.

All that being said, the lehmans are great, cheap to mainatain and repair, and if need cheap to rebuild. Our rebuild, including the fuel pump (1500 worth) and cooling system was about 6k australian.
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Old 04-24-2019, 01:46 PM   #26
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Just had out 120 Lehman "serviced" at a total cost of $ 6000.00. (Pat's Marine Engines in Seattle) Oil changes, filter changes, impeller change, engine anodes changed, exhaust manifold removed and machined, new exhaust elbow fitted with new exhaust hose with better "flow". Heat exchange taken off and thoroughly cleaned and put back. (Made a big difference in the amount of cooling water out of wet exhaust!) Some new hoses, all fresh fluids and oils.
Not cheap, but hopefully good for another 50 years! Engine only has 3500 hrs on it. Service engineer stated that diesels need to run and run often!! Work still interferes with the hobby!!!!
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Old 04-24-2019, 02:47 PM   #27
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GB3295 is there any chance you could post a video clip of how much water you are putting out of your exhaust at idle? I have the same engine and would love to compare.
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Old 04-24-2019, 02:55 PM   #28
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Last year Harbor Marine in Everett was quoting $17,000 plus a core. Try them or North Harbor in Anacortes for current prices.
I don't believe they are rebuilding Lehman engines any longer. Last year I was there for a motor mount casting and they said the fellow that did the rebuilding had health issues. But call them none the less, they are good people.
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Old 04-24-2019, 02:59 PM   #29
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Just had out 120 Lehman "serviced" at a total cost of $ 6000.00. (Pat's Marine Engines in Seattle) Oil changes, filter changes, impeller change, engine anodes changed, exhaust manifold removed and machined, new exhaust elbow fitted with new exhaust hose with better "flow". Heat exchange taken off and thoroughly cleaned and put back. (Made a big difference in the amount of cooling water out of wet exhaust!) Some new hoses, all fresh fluids and oils.
Not cheap, but hopefully good for another 50 years! Engine only has 3500 hrs on it. Service engineer stated that diesels need to run and run often!! Work still interferes with the hobby!!!!
I had work 10k$ worth of done at Pats several years ago. Most of the work was done well and I was pleased. Come to find out years later they repositioned the new motor mounts and changed the rear ones to being supported by the transmission. My shipwright in Port Townsend discovered this and said nobody does this. I called Pat and he denied doing it, which is weird. YMMV
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Old 04-24-2019, 04:02 PM   #30
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Most smaller engines stateside have rear mounts on the gear, front mounts on the front of the engine block. It can be done on the engine only, that can be ok too. I can't imagine anyone changing it unless there is a driving need to do so. That is a lot of work.
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Old 04-24-2019, 04:44 PM   #31
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I will certainly do that, but will be a while, as stated, work interferes with the hobby and my work takes me out of the country. Once done, I will post it for sure!
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Old 04-24-2019, 08:21 PM   #32
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FWIW, I have had two FL 120's rebuilt. Different reasons for each engine, though one was the number 6 cylinder issue that Bruce alluded to. Each rebuild ran into the low $20k's.

What I did on each occasion though was with the engines out I sent the gearbox's off to be overhauled. It is quite cheap once the engine is out to do this, and in all probability it may not have been needed. Still when they are reaching 30 odd years of age a little TLC is a good thing.

Speaking of velvet drive gearboxes, I was advised that for either the port or starboard box, parts are no longer available, sorry can't remember which one. Anyone heard of this?
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Old 08-11-2019, 04:14 PM   #33
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Rebuild

Picked up a 38' 2 years ago with a 120 in it. I've been wondering when my rebuild is coming.?
Stuck thermostat led to a blown coolant line to the expansion tank (keel cooled). Flushed the system and new thermo, everything seems fine. They really are simple engines. I've been thinking of sourcing out a block and parts to make a spare. Would be a cool learning experience.
After reading this awesome thread, I may be changing my tune?
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Old 08-11-2019, 05:25 PM   #34
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Speaking of velvet drive gearboxes, I was advised that for either the port or starboard box, parts are no longer available, sorry can't remember which one. Anyone heard of this?
All parts required for typical rebuild are available anywhere. e.g. clutch disks, seals, gasket sets, bearings, hyd pumps. Some parts are no longer in production. CR2 control valves are no longer made but the pistons are available so they can be easily rebuilt. Gears might be hard to source, esp pinion gears, but they rarely need replacement.
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Old 08-21-2019, 11:07 AM   #35
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120 Lehman valve adjustment or?

Hi! Not a mechanic and need advice. Not mechanics where I am. On our trip in from Prince William Sound I experienced a severe vibration. It sounds like chain sliding in the locker but unfortunately wasn’t. At about 17 hundred rpms it was in and out for short periods. Upon slowing it decreases in frequency. Could this be valve adjustment or clatter? I’ve never adjusted the Valves. Or should I look for shaft noise? Shaft bearing going out? It sure sounds like upper engine noise. No decrease in rpm or speed or power. I know this is vague. Going back to do more inspections today. 1982 Chb and single 120 Lehman. Thanks from Alaska.
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Old 08-21-2019, 12:07 PM   #36
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Check to see if you can hear about where it is coming from.



If you can hear it back near the bellhousing, might be a dampner plate...especially if all else seems normal.
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Old 08-21-2019, 12:17 PM   #37
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Thought I was on a different thread.
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Old 04-25-2022, 09:12 AM   #38
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Ford Lehman Tools

I recently bought a President 37 with 2 Lehman 120s and a Westerbeke genny which currently sits on the hard in the Bahamas. I need to take tools and parts with me from Florida to prepare it for the trip to the states. I am purchasing a set of tools for the boat. Which size tools are required to work on these engines? SAE? Or metric?
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Old 04-25-2022, 09:17 AM   #39
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SAE for the Lehmans.
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Old 04-25-2022, 09:19 AM   #40
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I recently bought a President 37 with 2 Lehman 120s and a Westerbeke genny which currently sits on the hard in the Bahamas. I need to take tools and parts with me from Florida to prepare it for the trip to the states. I am purchasing a set of tools for the boat. Which size tools are required to work on these engines? SAE? Or metric?
Welcome aboard and congrats on your new boat. The Lehmans are mostly SAE but there are a couple of metric things on them. I have posted the recommended tools on TF. I just looked and I don’t have the list on my computer anymore but you can search TF to find it. Sometimes Google search works better than the TF search.
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