DT466 Rebuild Cost [DIY & Pro Install]

The DT466 is one of the most reliable and resilient engines you’ll find in vehicles today. Originally made by Navistar, versions of the DT466 were in production from 1971 to 2016 and can be found in many medium-duty trucks.

There are many advantages to rebuilding a DT466, and it will be cheaper than a replacement, but you will have to factor in expenses.

On average, the rebuild cost for a DT466 is between $1050 and $3000. This price will increase if you want the engine to be rebuilt by professionals. That will normally cost between $2500 and $6000.

If you’re interested in what costs would be involved in a DT466 rebuild, read on to find out more about what these might entail. 

How Much Does It Cost To Rebuild a DT466?

Rebuilding a DT466 is a great idea that is more cost-effective than buying a new one or remanufacturing one. DT466 engines are so resilient that they make for great investments in any form, but you’ll be able to save a lot of money on a rebuild.

The amount you will pay will be determined primarily by the method you use for the rebuild, and whether or not the work will need additional factors that will add to the budget.

The cheapest method is to rebuild it yourself, but if you don’t have the know-how it won’t be the most practical choice. In general, this method can be done for under $3000.

Rebuilding a DT466 engine professionally will involve paying for labor costs, which is why the budget will usually double with this method.

You may see it go up to $6000. Choosing between these methods will be determined by your expertise and what will be most convenient for you in the long run.

Methods of Rebuilding a DT466

The cost of a DT466 rebuild will be influenced by the method you choose for the project. There are two primary ways of going about this task: the DIY method, and the professional method.

Before you proceed with the rebuild, you should decide which method fits you and your budget better.

DIY Rebuilding

This will usually be the cheapest method to employ for the rebuild of your DT466. If you’re looking for the least cost, this will be your winning option, but it requires plenty of involvement and enough expertise to know what you’re doing.

You will have to correctly rebuild an engine and ensure that it runs as it should.

If you don’t feel confident in your personal expertise but want to choose this method, make sure to talk it over with friends, relatives, or neighbors who may know more about the topic.

They will be able to guide you at least with the theoretical part of the process, and may even be able to lend you a hand with the rest.

Engine Rebuild Kits

When proceeding with a DIY rebuild of a DT466, it is recommended to purchase an engine rebuild kit. Investing in one will make your job easier because it will provide the most essential parts you’ll need for it. 

You will have to make sure to get the correct kit for your engine. This will have to match the engine version and the year of the make. For a DT466, for example, you will encounter different kits for different engine serial numbers.

A good tip if you’re buying a kit online is to include your serial number when selecting it.

After you’ve found the appropriate rebuild kit for your engine, you should choose the type of kit you want. There are several options:

• Overhaul Kits: These include cylinder kits, a head gasket set, a lower gasket set, a main bearing set, and rod bearings.
• Underhaul Kits: These include an oil pan gasket, a main bearing set, and rod bearings.
• Rering Kits: These include a main bearing set, a head gasket set, an oil pan gasket, and rod bearings.
• Inframe Kits: These include an oil pan gasket, head gasket and main bearing sets, rod bearings, connecting rod bolts, and cylinder kits.

You will have to pay attention to the dimensions you need for the parts included in each kit. There are narrow and wide versions of most of them, so you will have to do some research to establish the ones you need.

The kits will streamline the process and will take away some of the pressure on you, especially if you lack an assistant for this task. It is advisable to buy kits from reliable retailers and to avoid deals that seem too good to be true.

You can find great options from $1050 and up.

Professional Rebuilding

Taking the DT466 to be rebuilt by a professional will increase the budget but it will also give you peace of mind and save you time. Mechanics will know how to rebuild it with quality and efficiency.

You will be paying extra for labor costs, and in case they might require special parts for your specific engine, they will have an easier time sourcing those if necessary.

This is the best option if you have no prior knowledge of rebuilding engines. You can teach yourself with online research, but you may not achieve the same quality that professionals would instead.

If you want to make sure you’re getting the best possible rebuilding work, this will be the option to consider.

Depending on the car shops in your area, you may find professional rebuild options for as low as $2500. You may see this go up to $6000 if the project requires extra time or extra elements.

The more hours spent on it, the more the labor costs will add up.

Luckily, the DT466 has so many advantages that rebuilding it through either method will be worth it. Rebuilding will also be much cheaper than investing in a new one, especially if you’re looking for an older series.

What Other Factors Can Influence Costs?

On top of rebuild kits and potential labor costs, you may see costs increase if you require specific items to assist with the process.

These can include replacement parts or add-ons like injectors (ranging from $250 to $350), and oil coolers (from $300 to $600). You may also need to replace the o-ring seals.

These seals are specific to engines like the DT466 because they are the types of engines with wet liners. These allow them to be separated from the rest of the engine block.

This is a useful feature but it can also cause wear on the seals. They are behind most issues that affect DT466 engines.

What Else Will You Need to Purchase?

If you opt to drop your engine in the hands of mechanics, you won’t usually need to purchase anything for the rebuild. This may change if specific parts are required that aren’t available in the car shop, but they will tend to source the parts for you and add them to the bill.

If you go the DIY route, you may need to purchase additional items to help you with the process. Here are some ideas for what you could buy to make this easier:

• Engine hoists: These can help pull your engine out of your car. With DT466, this isn’t as hard to do as with other types, but you can still save yourself some effort by getting a hoist for your garage.
• Power pullers: If you don’t need an engine hoist, these can be a great alternative that will help you support the engine, especially if you already have a structure designed for this.
• Bars for load-leveling: These are great tools that ensure that your engine will remain straight while you’re working on it.
• Engine stand: This is where you’ll do most of your work on the engine once you get it off the hoist or the power pullers.

Other Useful Items to Consider

You will need to have several components to hand for the rebuilding, especially if you don’t buy a comprehensive kit. Some of the tools you’ll need include pistons, bearings, oil galley plugs, expansion plugs, crankshafts, and cylinders. In some rare cases, you will need to replace the flywheel. 

If the rebuilding project will be an in-depth one, you should also consider head bolts, exhaust valves, oil pumps, water pumps, balance shafts, camshafts, harmonic balancers, and engine sensors.

Even if you do this all yourself, you should consider consulting a professional about this step.

The more work you’ll have to do on the engine, the more you will have to know about how to get the right parts and how to get them to work together.

Take your time to plan exactly what you want to achieve in this rebuild, and then invest in the right parts for your project.

Bottom Line on DT466 Rebuild Cost

A DT466 engine is worth being rebuilt rather than replaced. You can rebuild the engine either by applying your research and expertise to do it yourself or leaving it with mechanics.

If you do it yourself, you may spend between $1050 and $3000, but will usually be able to keep the cost under $3000. 

If you go for the professional choice, your budget may have to stretch to a range between $2500 and $6000. These costs will vary for both methods if additional elements or time is necessary to complete the job.