2003 Injector issues

[Joseph Donnelly]

Per the note above, definitely get a secondary filter system; I used FASS. Whatever, get the 3 micron filter. Bosch wanted at least 4 micron filtration for the common rail systems, but Cummins and Ram did not step up from 10 microns until years later.

 

[JFulford]

The Job is done! No smoke, smooth idle. I'm slow but persistent. Thanks for all the help and suggestions. It made a difference. Great Forum!
jeff

 

[Mschuman88]

Nice work! How did you end up torquing #6 line?

The Job is done! No smoke, smooth idle. I'm slow but persistent. Thanks for all the help and suggestions. It made a difference. Great Forum!
jeff

 

[JFulford]

#6 torque with a line wrench crows foot. However, I spoke too soon. Idling for 10 minutes, a few revs, and everything looked fine. Next morning, took it to the highway, got to the end of the entrance ramp, and it started "missing" and putting out a ton of white smoke, but did not quit running. Nothing I could see on the shoulder. Drove it 30mph to the next exit and looped it back home. Still very rough and smokey. At around 40mph, it did smooth out in this area, but still putting out smoke. Shut it down at home, and it restarted immediately, but still rough with smoke. Looks like more money and time.

 

[JFulford]

Ok, It has been a while. Long story sort of long, pulled valve cover. #6 intake rocker had LOCKED up. #2 intake was acting a bit squirrely when we tested the on and off injectors. Purchased used rocker set, intake, exhaust, bridge and pushrod and replace #6 parts. Removed #2 injector, looked at it, ohm'ed it out, all looked good. Ohm'ed them all and they all looked good. Retorqued everything and checked valve adjustment again. Changed the oil again.
I now have 7 hours on the truck, with 4 hours on the highway @ 70 ish. No issues and what seems to be better fuel mileage(hand-measured). Just can't figure out why #6 intake had locked up when I had not messed with it at all.
Thanks for the help, guys.
jeff

 

[Wayne M.]

Jeff, so you’re saying #6 intake rocker seized on its shaft?

 

[JFulford]

Jeff, so you’re saying #6 intake rocker seized on its shaft?

Yes. When we got it out, had to lightly hammer it to get it to move again.

 

[cerberusiam]

Just one of the failure points on the 5.9 rockers, they gall the shaft and that can happen. The updated 6.7 rockers have addressed that issue.

 

[Ozymandias]

Just one of the failure points on the 5.9 rockers, they gall the shaft and that can happen. The updated 6.7 rockers have addressed that issue.

Can they be retrofitted?

 

[cerberusiam]

Yes, rockers push rods, etc., should be a direct swap.

 

[JFulford]

Wow. Didn't know that. Also, I was out to lunch when I said #6; it was NUMBER 5 intake! #6 was ok.
So, I can retrofit my 5.9 with 6.7 rocker arms and pushrods?
jeff

 

[cerberusiam]

Yes, the 6.7 rockers and shafts and push rods interchange. The rocker shafts have extra grooves in them to promote better and more complete oiling of the shaft.

 

[mfurrh55]

Yes, 50 each.
jeff

May I ask who you got the injectors from?

 

[JFulford]

Dieselogic