The beast had major problems from the start!  Yes, she was running very well started right up and I can still start her up!  I was told the engine was rebuilt but I have my concerns about that?  First how well?  When I got to her she was missing parts for the fuel side and of course got that all straightened out! No leaks at the head gasket at first but the rockers where oozing oil out and to me that is the first sign that it might have been a hack job!  If i where taking the engine apart I would have had it buttoned up nice... Most important is I just replaced both coolers and they where clogged with silicone gasket ect.  Not something that an engine rebuild say in the last 8 years would of had done to her!  I will like always take the head apart and fix her right!   I have way to much time and money to let her sit around!  No I am not going to doze the rest of hawaii just about 30 acres... I have toyed with selling my D7G and D9G and buying a D8 high track!  But I quickly find that just because I will pay $140,000 for a newer dozer doesnt mean that I am getting a better dozer!   Yes, I am concern about the D9G meaning torque converter and transmission...But at the end of the day once I get her straightened out she will probably outlast something newer and I know what I have!  The engine as people have pointed out probably dropped #1 cylinder liner... which does not allow for the bite of the head gasket... Needs to be shimmed and straightend out!  Same for the rest of the engine... I am not confident with an engine rebuild especially when the fly wheel if we recall was out 180 degrees.  I know for a fact that was replaced... But again that does not mean that the mechanic that fixed that did a great job... I would say an awful job as I am meticulous and it might take me time but I will sort the old girl out!  

Sheesh! yea, those silicone Goober mechanics! tells how its been "rebuilt" I've also heard of "mechanics" using a block of wood and a sledge to drive the liners in, sheesh! you should be able to ease them in with the correct bar or liner installer, then you can feel them seat good and not chance cutting the o-rings.

oh good you're not going to deforest Hawaii !!

-30 acres is barely a warm up for D9
-yes it sounds like a very sloppy mechanic
-i understand wanting to have it run and operate properly, no leaks etc etc but that doesn't require a new engine

-have you lashed the valves before you tear into it? that reveals a lot of possible issues as well?

Yes, all valves have been re-lashed and to be honest prior to the head gasket I felt the engine was purring like a CAT!  I rebuilt the injection pump and loads of other items.   I believe we had one of the longest threads on ACMOC and we covered a tremendous amount.... You guys are amazing... I finished up the job today for my neighbor and am going to limp the D9G home!  I have not used her since I realized the headgasket blew!  I am not looking forward to her being moved but I need to to get to work... Probably wont be for a month as I have a couple other looming deadlines infront of the beast!  I will take pictures and all throught the process... Yes 30 acres is nothing however Hawaii is rough on equipment and she is an old girl.... It is a big job for her trust me... It means sorting her out... 30 acreas to doze here is big money over 100k easily.... What is everyones thought about newer dozer D8N????

The best advice anyone can give you right now is try the easy fixes first before tearing that engine to pieces, you might find it is just something simple.

Pull one head and see what you see, if the valves, bores and piston tops look like they haven't been touched in 30,000 hours then figure on pulling the other head too and maybe going deeper like new rings, but if the engine was purring and working well before this issue, then that gives you some confidence it can be returned to that situation again, perhaps with just a new head gasket and proper torqueing of the heads, who knows, maybe the last "Mechanic" only had a torque wrench that went to 160 pounds, or maybe they over torqued and pulled a couple of head studs, I've seen some weird stuff with these old girls............

Appreciate that Mike!  yes some very weird stuff! The head bolts as you said and I am hoping were not torqued down properly! I really do love the old iron I just did not get the seat time I should have!  But then again it is what it is! I will keep everyone posted on progress... 

Thanks Neil!  I keep going back and forth as I am probably going to pull from the mainland!  If I go that direction meaning buying a newer dozer than it of course needs to be shipped and that is major money close to 20-30K.  I just dont trust the newer iron as it is not as reliable so they say as the d9G and the D9H.   But all the big outfits here are running newer equipment!  I love dozing and want to enjoy not keep wrenching everytime I am on a peice... I get a hose and maintenance and all buy the D9G has burnt me out a bit!  Time for me is most important as we are building a new house and even if I wanted to have someone else sort her out there are few and far mechanics here that I trust and even know how to work on the old girl... Sorry for the rant.. Appreciate your advice...

Computers are great but something to be said for a machine that can run without one.