Well coolant started to getting into the crankcase. Head gasket proved to be fine. Sleeve O rings proved to be fine.
Sleeve #4 cracked around the two lower O ring grooves. We had reused the old sleeves and pistons. After the first 5 hours we changed the oil and it was free of coolant so not sure when it cracked. That is a very thin area of the sleeve.
We have the old sleeves out and the block washed out with gas as of late last night so after a dry inspection we plan to order a new sleeve, piston, rings rod bearings and sleeve o-rings set.
The shop owner let me clean up and hone the old sleeves so I got a lot of first time experience going that deep into an engine. Wish this had not happened but on the redo we are going to revisit the steps. For some reason one rod bearing had a small hot spot showing. They were all at .002 clearance per Plastic Gauge. The crank looks clear rod wise. We did not drop the crankshaft caps.
I wanted to go with the standard 3 3/8" bore but it looks like the thinner 3 7/16" over bored sleeve kits are the only option. I am more concerned about forces on the crank than engine HP.
This time I plan to start with the Archoil AR9100 from the first fill of the crankcase and may just go with the Rotella T6 5W-40. The last time I ran 15W-40 diesel oil without the AR9100 for the first 5 break in hours.