Got my M38 running for the first time in several years. The original engine had a large crack in the block, unrepairable, coolant in the oil, so it got pulled and I eventually found a military block to install. Thought I had everything covered last fall (rebuilt engine, transmission, brakes, clutch, axles, generator, etc.), filled it with coolant, then saw pools of coolant on the floor. Water pump leaking like a seive. Changed out the original water pump with a new one and tried again. Once more, pools of coolant, pouring out the tailpipe. Found an internal hole in the block (that's another long story). Out comes the engine and off to an expert welder for a repair. Comes back and I drop the oil pan, clean it out and reinstall the engine, hook everything up. Time to start - she turns over but won't do anything but puff. Again I see a pool of coolant under the tail pipe. WTF! Off comes the head and there's coolant in the cylinders. Check the head and block - no cracks, all head stud holes were properly sealed. Start cleaning the Spray Tack Copper sealant from the block, head and gasket. I see something protruding from one of the punched holes in the gasket - looks like a bit of fluff from the fiber side. No, its hard, out it comes with pliers - a chunk of metal stamping, corregated like a potato chip, about 1/8 x 1/4 inch - just large enough to keep the head gasket from sealing! Never saw it when the gasket was first installed. New gasket from the auto parts store (a free exchange and they had one in stock for a change, guess they saw me coming), cleaned everything up, bolted everything down. Primed the engine with oil, added coolant in the LAST thing and tried again. She started! Really smoked a lot but soon settled into a nice snarl with no smoke. Wife stood there watching like a deer caught in the headlights holding a fire extinuisher. This was the first time the engine had run after a rebuild by the PO about 15 years ago. Shut her down, retorqued the head and started it up again. Below is the result (click on photo for a short video). Sounds gutteral because the muffler is not on yet. A big thanks to this site and all its contributors, Wesk and Ryan Miller. You may not have had your hands on the wrenches, but you guided me to get this jeep back together. Another M38 on its way back to the road because of your care and dedication to this website. Stick around tho', electrical is next!
P.S. Had to inscribe a new timing mark on the engine pully (per WesK's instructions), clocked the oil pump to the correct position (per WesK), set up the distributor for firing at the the new mark (per WesK). Checked the timing when I had it running - it was absolutely dead on! That felt good. Thanks Wes!
