'05 Budget Engine Rebuild

[Timd32]

@GAmes has posted several times how he handled his build and engine. Maybe he has some insight.

They are beasts for sure becareful.

 

[Dysfunctional Vet]

It probably goes without saying but a good seal job on the bottom end gaskets and such, rear main front, oil pan, timing case/cover, cam seal etc. I really recommend using Permatex high-tack gasket sealant on hard to align gaskets, o-rings or any sealing surface with a gasket really. It's essentially an oil, fuel and water resistant high temp glue that stays tacky indefinitely. I used it on my oil pan gasket, oil pickup tube, and rear main housing. It's also a good thread sealer.

Engine mounts while its out if they look bad.

Cp3 if its weeping diesel.

Will do, thanks for the heads up.

 

[BigPapa]

DV, somehow, you're typing your reply inside the quoted post. Make sure to begin typing your reply after the "[/quote]"

 

[jghflys]

I'm seeing consistent "low" mileage rebuilds and excessive blow by engines(mostly stock applications) in passing weather on marketplace or groups.

My son's 2006 2500, and my 2005 one ton both broke rings before 200K miles. His was run hard with a tuner, and mine was was frequently used for towing heavy loads. My local shop called it as broken rings and said it was due to ring gap too tight from the factory. His was in #6 and mine #5 cylinder. Both of us had excessive blow by and blew oil out of the vent tube. Your 2003 is outside the range he mentioned, 2004.5 to 2007.

 

[Darkbloodmon]

My son's 2006 2500, and my 2005 one ton both broke rings before 200K miles. His was run hard with a tuner, and mine was was frequently used for towing heavy loads. My local shop called it as broken rings and said it was due to ring gap too tight from the factory. His was in #6 and mine #5 cylinder. Both of us had excessive blow by and blew oil out of the vent tube. Your 2003 is outside the range he mentioned, 2004.5 to 2007.

Was there ever a Chrysler TSB or recall for this issue?

 

[jghflys]

Was there ever a Chrysler TSB or recall for this issue?

I never looked. The opinion was seconded by the shop that did the rebuild for me. They custom fit the rings to their own specs.

 

[AH64ID]

Was there ever a Chrysler TSB or recall for this issue?

Not that I am aware of.

 

[Timd32]

When I searched "Piston Ring" on a 2005 set up, it's not what was described above individual cylinder related, but was interesting and seemed on topic enough to share.

 

[Darkbloodmon]

When I searched "Piston Ring" on a 2005 set up, it's not what was described above individual cylinder related, but was interesting and seemed on topic enough to share.

I'm skeptical that majority of the ring breakage issues are air intake related, seems like a lack luster front/excuse to pass on high-mileage warranty claims onto owners.

I wonder if any high mileage real-world testing is done to effectively survey and collect data on issues like this? Or do they just stop testing on anything past the specified powertrain warranty?

 

[Dysfunctional Vet]

 

[Dysfunctional Vet]

Pulled the engine. Gonna try and get the head off in the next week.

 

[Dysfunctional Vet]

DV, somehow, you're typing your reply inside the quoted post. Make sure to begin typing your reply after the "

"[/QUOTE]

Thanks BP. I'll try to get it straight. I'm not very tech savvy.

 

[Dysfunctional Vet]

Tore the 5.9 apart today.

 

[Dysfunctional Vet]

 

[Dysfunctional Vet]

Had a broken ring in #6 and another broken ring in #1. The crank journals in #s 6 and 5 were not perfect but won't catch a fingernail.

 

[Dysfunctional Vet]

I might be going crazy but I can't find all the pieces to the #6 broken compression ring.

 

[Darkbloodmon]

How many pieces was it broken into?

Additionally would the spray pattern on piston bowls 1 and 6 be any indication to injector condition and perhaps a related failure? I can't see 6 as well but around the outer edge it looks like there's a pattern, 1 is pretty defined. Are 5 through 2 like this?

 

[Dysfunctional Vet]

View attachment 13091

3[/ATTACH]

 

[Dysfunctional Vet]

Injector 6 did look different. The tip was "fouled looking". Meaning I could see the spray holes easily on the other injectors, but not #6. The ring on #6, I'm assuming, was in 3 pieces, but I couldn't find the third piece. I'm wondering if it didn't fall into a coolant passage as I popped the piston out of the top of the block. My big concern is the crank journals and the cause of the cylinder damage. Was it a bad injector or an overheated cylinder from insufficient coolant flow. Still learning the technical aspects of cummins. I'm not an expert, just a shade tree mechanic. Sorry about the duplicate pictures I'm not tech savvy at all.

 

[Dysfunctional Vet]

I'll try to see if I can post more pictures PROPERLY.