"04.5 KA-POW (Now What)

[ceaman]

I do like the 555 motor better but the truck wouldnt be a 555 motor ... with the 600 ECM program, electronic turbo and the 04. 5 exhaust... Rather it would be some odd breed with no future knowledge of how to buy parts... . in fact is it even an 03-04 555... what if it is a 2nd gen motor? What motor is it at all?



Any one have any sugestions on how to determine exactly what long block they are putting in the truck?



My latest thought is about the piston oil cooling nozzles... if it isnt a 600 long block will it hold up to 600 EGT's

 

[GarrettS]

I have 8000 miles on my 04. 5. I have had two injectors go bad on it already. Its stock right now except for the AFE. I'm kind of hoping for a third one, then its a 05 for me

 

[DBoyd]

Why isn't Cummins doing a recall on these bad injectors??? Looks like that would be cheaper than supplying a new engine when one fails!! Man oh Man!! If it isn't KDP, it's lift pumps and injector pumps or the dreaded front end shake and who knows what else?? Think I'll start hauling a bicycle just in case!!!

 

[Kirwin]

Bicylce? Not for me, thats why I'm keeping the 97!

DBoyd, I'll take a mechanical lift pump and a mechanical injection pump any day! Don't need no stinkin cam position sensor or crank position sensor to make my truck run! (Won't run for too long without that RPM sensor down on the vibration dampener I guess since the alternator won't turn on. ) I can fasten the fuel solenoid up with some string or just jumper off the battery to keep it energized to keep the truck running. Heck I did this to get home on the old truck when I burn't up a fusible link one day. Mechanical injectors are just miniature relief valves with YEARS of dependibility testing behind them. I've never heard of a 12 valve melting a piston when a mechanical injector failed! All the above IMHO. Ken Irwin

 

[Patriot_RAM]

driverno --



I just wanted to let you know that I too had read your message about how Banks treated you. I was originally going to go with their 6 gun system until I read about your misfortune and how they mis-handled it by ignoring you. Me and several of my buddies have gone with other systems due to their ignorance toward customer service. I have both the TST and Edge EZ on my truck now.



Thanks!

 

[Pit Bull]

DBoyd, I'll take a mechanical lift pump and a mechanical injection pump any day! Don't need no stinkin cam position sensor or crank position sensor to make my truck run! (Won't run for too long without that RPM sensor down on the vibration dampener I guess since the alternator won't turn on. ) I can fasten the fuel solenoid up with some string or just jumper off the battery to keep it energized to keep the truck running. Heck I did this to get home on the old truck when I burn't up a fusible link one day. Mechanical injectors are just miniature relief valves with YEARS of dependibility testing behind them. I've never heard of a 12 valve melting a piston when a mechanical injector failed! All the above IMHO. Ken Irwin

Ken I have to agree, it seems like Cummins is getting more complex to handle the emissions issues and with this complexity the CTD has become a problem prone engine that is now not anymore dependable then the other diesels that are trying to meet the emissions requirements. Looks like the ideal would be to find a mint 12 valve if you want a long running CTD. Other wise you need to trade when the warranty expires. What a joke Even if you have one without problem you never know when the next shoe will drop and if you are out of warranty you will have to come up with $8K for a new CTD engine that you still can't count on.

 

[ceaman]

I received a call Thursday from the Service Manager asking why I would call DC Customer Service on them. I told them I felt someone had dropped the ball on getting my truck repaired. That someone has to be the one held responsible and that after trying 2 times to contact the General Manager with no returned calls. The mechanic answers to the Service Manager. When I contact DC customer service, the first thing they do is put me on hold and call the Service Manager, to get both sides of the story. So since it all revolves around him... . He is the one I am complaining that dropped that ball.



Without going into to much detail, He denied ever giving me any timeline on the repair and stated that the truck was fully assembled and ready to leave the shop other than the starter. That the replacement starter they ordered came in and is identical to the starter which came off of my original motor. He said that there is a 1. 25" spacer keeping the starter from mounting. I was told that the spacer can't be removed without approval from STAR and that the transmission might have to be removed as well.



I spoke to DC Customer Service again on Thursday, after my call from the Service Manager. They said that my file would be forwarded to the District Manager, the Dealer, and the Business department.

 

[DBoyd]

Hey Pitbull and Kirwin, I agree with you all 100%. That's why I am keeping my 97 12 valve in the garage with 50K miles on it. I'll put the miles on the 99 till I trade for something else. But the 97 is stayin!!!! I can work on it and not have to worry about codes and electronics etc. And the KDP fix isn't too bad so I got to get that done. Then it's about bullet proof!! (Unless it's a 53 block!!)

 

[Pit Bull]

Hey Pitbull and Kirwin, I agree with you all 100%. That's why I am keeping my 97 12 valve in the garage with 50K miles on it. I'll put the miles on the 99 till I trade for something else. But the 97 is stayin!!!! I can work on it and not have to worry about codes and electronics etc. And the KDP fix isn't too bad so I got to get that done. Then it's about bullet proof!! (Unless it's a 53 block!!)

I use to worry about lossing lift pumps and then the injection pump on my 2002, but that is nothing cost wise compared to killing the engine with a cylinder meltdown, taking out the entire engine. Progress ain't it great



PS- I agree hang onto that 97 12V

 

[rbattelle]

ceaman - glad to hear calling DC customer service made some people nervous. It means at least some of the time calling customer service works. I'm curious what the 1. 25" spacer is and why it needs to be removed. Is it something that comes shipped on the engine that they're supposed to remove before installation?



As to the reliability issues, I agree that the electronic engines are somewhat less reliable than an old 12v with mechanical jerk pump and injectors. I don't think anyone can disagree factually that a jerk pump is more reliable than a common rail system. Knowing what I know now, if I had been given the choice with this truck between the common rail engine I have and a 12v engine, I'd have taken the 12v. In my personal opinion, the 305/555 engine is less "bulletproof" than a 12v (or maybe even a 24v), but more "bulletproof" than the "600" and up engines (due to no emission equipment and lower operating temperatures, if nothing else). Of course, since I own a 305/555 engine I suppose I'm a little biased.



Anyone know the relative difference in part counts between the 12v, 24v, 305/555, and 600 engines? I suspect the 305/555 has the lowest part count of any of the engines, but that's just a guess...



-Ryan

 

[ceaman]

Well we are all wondering what the spacer is... . its the one thing holding up mu truck from being finished... STAR supposedly doesnt know either

 

[DPKetchum]

I bet engines are shipped through and from STAR. Not through your parts counter. I know that STAR won't ship a engine until ALL serial numbers are accounted for etc. Normally anything to do with engines all numbers off it are required to order so unless minor production changes I can't see a "differant"engine being shipped etc. Someone has the answer to shim and what not.

 

[Pit Bull]

This whole thing makes me sick, I wanted to get a new CTD, even though I don't need to tow huge amounts. I wanted it because it was a beast and would run forever and get good MPG. Looks like that dream is a thing of the past Since my tow requirements will be 7K lbs on infrequent basis, I guess I need to look for a 1/2 ton Pickup that cost a ton less and will be more dependable. Maybe I can find a good used CTD 12V

 

[BHolm]

Even though it looks like my new (5,000 miles) truck has a failed injector, I wouldn't write off the CTD completely just yet. I have 2 '03s that have been perfect trucks. Before I bought those trucks and before I bought the '05 I watched here pretty closely to see what was going on. I had a Duramax and on thier own site a poll reveals a 20% injector failure rate. I don't see anything anywhere near that here.



I have to wonder about the "bad batch" threory on injectors. ceamans truck was an '04. 5, my truck is an early '05, early enough that it qualifies for the 1837-04 tsb. Is that first batch of "600" injectors to blame? I don't see 555 engines doing this, and please don't just tell me I missed the threads :{



The biggest problem I see is DC not getting off thier duff and taking care of these things ASAP. WEEKS for a repair on a new $40k truck is NOT acceptable. ceaman you must be a saint as I would have crawled down the thoats of several DC executives by now I like my dealer and all, but when I get the story about a long wait for the parts my truck needs I will be going way over thier heads that day. I understand they want to help me and STAR or DC customer service, or whatever they call themselves are the ones holding up the show.



What should have happened is that you should have had that truck back on the road in 3-4 days, one day to yank it while the new one is in route, one day grace on shipping and one more day for installation. This was a warranty failure, your truck was stock, and you need it for your livelyhood. The fact that it is weeks later is what worries me and prospective buyers most.



The really sad part is that in my experience you have to nearly become a raving lunatic to get them to act. Doing the right thing because they can and should doesn't register with them. Case in point my D-max. GM customer service wanted me to wait two weeks for a "certificate" for the service my truck needed. The truck was in the shop at the time. I told bozo on the phone to call the dealer and get it done immediately and they could screw with THIER system on THIER time. It worked, the truck got done by the next morning.

 

[rbattelle]

Sometimes I think the new #1 rule in business is:

"Our time is valuable, the customer's time is free"

They don't care if you're without your vehicle for 2 weeks... it costs them absolutely nothing (except you complain to your friends, but that's hard to translate into $).



ceaman - any chance you could snap a pic of this spacer?



-Ryan

 

[Pit Bull]

When I went by the Dodge dealer yesterday I noticed on the window stickers that it stated the drivetrain warranty was 7/70. Does Dodge still warrent the CTD for 100K miles or is it now only 7/70?

 

[ceaman]

BHolm



I agree totally with your last post! I have often felt that the TSB is a patch or cover up for the bad injector trucks.

ceaman - any chance you could snap a pic of this spacer?



-Ryan

I could if it was my local dealer and I didnt have to drive 250 miles from home too see the truck.



Its at GANLEY DODGE in Bedford Ohio.



And Pit Bull..... yes its 100K on the engine... but it isnt thru Cummins its thru Dodge.

 

[RTuvell]

I've been following this thread from the beginning and I have to admit that I still don't quite understand if there is a general conclusion to be reached here that describes the problem resulting in engine failure.



Is there a belief that a specific model year, date of manufacture, injector part number, operating condition, or something else that should alert us of a potential problem?

 

[rbattelle]

BHolm

I could if it was my local dealer and I didnt have to drive 250 miles from home too see the truck.

Oops... forgot about that little detail. I wonder if there are any TDR members that live in/near Bedford?



-Ryan

 

[ceaman]

Talked to the Service Manager at about 4 pm. he said the transmission has been removed from the truck to exchange the adapter plate from my old engine to the new engine. Then re-install transmission and test run the motor... told me to call them tomorrow around noon and see if the truck is finished. I will try to get photos of the odd ball plate that is on the rear of the engine, when I go pick it up. The plan at the moment will be to pick it up on Wednesday.