'04.5 Chug Chug (the sequel to "04.5 KA-POW)

[ceaman]

Ok to the ones who know what I’ve been thru I wont tell the history, for those who don’t... . look at this link.



https://www.turbodieselregister.com/forums/showthread.php?t=117560



As for the sequel to the story... I am 50 miles from Albuquerque, NM with 100,115 Miles with a engine that wouldn’t run on Friday. On Monday after many calls to find help I am put in contact with the New Mexico District Manager, He was polite and very helpful in getting my truck towed to the nearest dealer (Zangara Dodge). Upon arriving at the dealer they immediately checked to see what was wrong and found an injector (#3) was stuck open (tested by blocking fuel from the rail to that injector). A new injector was ordered and then installed today (Tuesday). The Tech starts the engine and just makes it out the garage door when the motor dies, upon trying to restart the engine wont crank over, using a pipe wrench the engine still will not move!



Removal of the head became the next order of business. Upon removing the exhaust manifold I was handed corn kernel sized pieces of piston from the #3 port. NOT GOOD! Then when the head was lifted off you could see the broken and bent valves, one of them embedded vertically into the top of the piston. As well as seeing the new injector tip had been smashed.





Not bad for a motor with one month and 12,000 mile on it!

 

[Vaughn MacKenzie]

OMG! NOT AGAIN!!!!! :{ :{ :{ :{

 

[Vaughn MacKenzie]

Well I read back and see you have a new truck coming. I wonder how this will play into it now that D/C is getting a totally DOA truck in return?



Man after this has happened again I wouldnt blame you for not having a good feeling about going with another new Dodge/Cummins.



The HPCR system has some nice advantages, but because the system is super pressurized any injector problem could lead to a constant fuel stream into the cylinder and result in a torched piston. . . a definite drawback of the HPCR technology.



When is your new truck due? Sounds like it might be time to just hand the keys to D/C and wait for the new ride. . .



Vaughn

 

[ceaman]

The new one is ordered but i have no date on the arrival... .



Dodge is repairing this truck but it may not be done before the new one is in... . problem is im 1400 miles from home (and the new one)..... and this one needs to be there for the swap.

 

[RJOL]

Okay... Message to self... Stay calm... This is the "one in a million disaster story" ...

 

[MMeier]

Damn Jeremy, I feel for you man!! I would hope under the circumstances that D/C would pick up the truck where it is, but based on my experiences with them I wouldn't hold my breath!

 

[FDavid]

Sorry to hear about your (bad) luck. I am sure thats something that would shatter your confidence in Cummins for a long time. If that happened to me the only Cummins I would ever buy again would have no more than a dozen valves



Dave

 

[Vaughn MacKenzie]

ceaman did you reinstall your pyro? How bad were the EGTs? I would strongly recommend going pre-turbo on the next truck. I think putting the load to these hot-running motors would virtually necessitate running pre-turbo so you can really see how hot it's getting and enable you to control temps more readily with your right foot.



I know it was a bad injector not high EGTs causing the failure but just making a suggestion for your next truck.



Good luck with everything, I don't like reading stories like this



Vaughn

 

[rbattelle]

This is the most amazing story I have ever read on here, I think.



2 engines!? 2?? You and these engines are like garlic and Count Dracula.



Clarify for me: is this the new engine that they installed in your truck, or was it a loaner vehicle they gave you while you're awaiting your new truck?



-Ryan

 

[ceaman]

This is the most amazing story I have ever read on here, I think.



2 engines!? 2?? You and these engines are like garlic and Count Dracula.



Clarify for me: is this the new engine that they installed in your truck, or was it a loaner vehicle they gave you while you're awaiting your new truck?



-Ryan

Ryan,

This is the new engine that was installed in my truck last month in Ohio.



Vaughn,

I never reinstalled the pyro to pre turbo. When I picked it up it was still installed post turbo in the elbow. EGTs on this motor were never beyond 800 degrees when this motor quit running with me in it, I have no idea how high they were when the Tech was pulling it out of the garage and it locked up.



this question leads me to question how to accurately install the pyro in the exhaust (for the next truck) if the exhaust manifold is divided the way it is... . on my next truck do I shoot for the #5 cylinder run..... because it was #3 this time... . so being on the back half of the manifold wouldnt have found this one either... ...



I KNOW 6 EGT GUAGES! Anyone have a pod for 6 egt, 1 boost psi, 1 trans temp, 1 lift pump fuel pressure, and how about a fuel rail pressure guage too while were at it!?

 

[TFucili]

Ten extra gauges means you would have to contact the FAA to obtain your instrument rating... :-laf

 

[FATCAT]

Sorry to hear about your (bad) luck. I am sure thats something that would shatter your confidence in Cummins for a long time. If that happened to me the only Cummins I would ever buy again would have no more than a dozen valves



Dave

Note to self:

Keep my present truck in tip-top-shape ... it will be worth a fortune in the near future (aka a collector's item) ... . hummmmm.

 

[FATCAT]

Sorry to hear about your (bad) luck. I am sure thats something that would shatter your confidence in Cummins for a long time. If that happened to me the only Cummins I would ever buy again would have no more than a dozen valves



Dave

PS: FDavid, I'll sell you my truck for a mear ... lets say $35,000 ... to start. :-laf

 

[FDavid]

PS: FDavid, I'll sell you my truck for a mear ... lets say $35,000 ... to start. :-laf

Peso's?! You got a deal! :-laf



I sold my 97 in decemeber and my 95 in january.

Maybe I should of kept one as a back up!

Dave

 

[ceaman]

Ten extra gauges means you would have to contact the FAA to obtain your instrument rating... :-laf

ROFLMAO! IFR... . ive been VFR for years... ... wonder if they wouuld classify it as experimental?

 

[TFucili]

Glad I could make you laugh, despite your problem



As a potential owner some of these threads are disturbing :{



Good luck to you.

 

[FATCAT]

Peso's?! You got a deal! :-laf



I sold my 97 in decemeber and my 95 in january.

Maybe I should of kept one as a back up!

Dave

Ummm let me think ..... NO DEAL . . Me no hablo peso's. :-laf

 

[CJEliassen]

JPI and GEM make a 6 probe EGT system all on one display. I think it is about 1,500 bucks at the cheapest.

 

[swexlin]

Me no hablo peso's

"I don't speak pesos to me?"



Anyway, back to the thread - Ceaman, I got rid of my Ford PSD for MUCH less than you have been through on this truck.

 

[ceaman]

The latest news on the truck and its repair is... .

STAR threw up the red flag and said no engine replacement for this vehicle. They said that the engine was replaced 12,000 miles ago and it wasn't going to be replaced on a high mileage, arbitrated vehicle, told the tech that if there was a problem with the decision for the service manager and the NM district manager to contact them. That parts will not be shipped.



I was given no option by DC as to how to get home (1300miles) No hotel or rental car reimbursement. I was told to clean out the truck as I might not see the truck again. (But I still get to make the payment and the insurance untill the new truck is delivered)



I cleaned out my truck and searched for methods to get me and my trucks belongings home for most of the day. I stuffed all I could into the trucks toolbox with stuff left over, then removed the box from the truck. Greyhound $149 & 3 days but no way to ship my toolbox. Airfare was $300 with no way to ship the box. Hertz rental for a mini van was $849 plus tax. Uhaul for the smallest truck is $965 one way. Some other rental car places were over $1,100 one way.



I ended up getting lucky as a driver who works for the same company I do (Starfleet) heard of my trouble thru the grapevine and called and offered me a ride home. We loaded my toolbox into his FORD using the forklift ( :{ why does a Ford have to take the Dodge guy home? :{ ). We are leaving in the morning for home.



I do owe a great deal of thanks to the service department at Zangara Dodge as they have treated me great and offered every piece of help they could. I also owe a thank you to the New Mexico District Manager who helped to get the trucks problems diagnosed.