05 CTD Turbo failure

[J D Moore]

This was posted on the Arctic Fox (Northwood) forum today

Northwood RV Owners Association Forum

 

[JApol]

We need your log in to see it :-laf

 

[seafish]

Can't log in... maybe you could just cut and paste the OP story here ??

 

[J D Moore]

The following is the story from the forum. Sorry, I thought non-members could "lurk" just not post.

05 Dodge Diesel Turbo Failure
05 Dodge Cummins TurboDiesel 5. 9L with 107,000 miles. Have had zero problems with this truck and engine..... until now. While accelerating up a grade on I-81 near Roanoke, VA we suddenly heard a very loud "boooom" in the engine compartment followed by a high pitched whine then the engine went totally dead. Luckily we had enough forward momentum to make it safely to the shoulder and out of harms way.

Good Sam arranged a combined tow (truck and trailer) to a nearby garage that could handle the diesel. Troubleshooting revealed a blown turbo. The turbine wheel exploded and scattered metal fragments throughout the turbo case and manifold. As a precaution the mechanic said they would have to pull the head to inspect for any metal particles that may have made their way into the engine and caused additional damage. At this point we are still waiting the verdict on the condition of the engine but it may be a week or more before we get back on the road if we are lucky. The engine shop towed the trailer to a nearby campground so we are camping until the work is done. Anyway you cut it, this will be an expensive trip especially if there is any significant engine damage. Life on the road!

 

[jakprince]

I dont understand why a blown turbo would kill the engine. Or how any pieces of it could make it through the intercooler. One good part is there is a cummins place in roanoke if you need any parts.

 

[AH64ID]

If truly was the turbine side that exploded there is little change there is anything in the intake side.

 

[MChrist]

Pulling the head sounds quite drastic. Sounds to me like somebody is looking to pad the bill!!

Don't be surprised if they come back with " yeah, we found some shrapnel in your head. Good thing we pulled it!! If we didn't pull the head, your whole motor would've blown!!!"

Am I the only one who feels this way??

 

[AH64ID]

I agree...

Start with pulling the intercooler and see if any metal is in there, if not. . leave the head on!

 

[seafish]

NOT saying this can't happen, but have NEVER heard of this happening on a stock turbo before today... I wonder if he had fueling or boost mods... .

 

[Bill Stockard]

NOT saying this can't happen, but have NEVER heard of this happening on a stock turbo before today... I wonder if he had fueling or boost mods... .

There's a VA in his signature... could that be a Van Aaken box?



I ran one of those briefly on my '00 3500 dually 6-speed on one trip towing our 31' Hitchhiker II fifth wheel. It made a lot of noise in an other wise quiet NV5600 in 6th gear. I took it off as soon as I got home and felt lucky to get my money back when I sold it.



Bill

 

[J D Moore]

My post is a copy of a post on the Northwood Owners Forum. My sig does not apply to this situation. Yes, VA is VanAken, I have used it continuously for many years without problem. I see it as restoring the HP/Torque that was downsized because of the auto trans in '99.

 

[J D Moore]

Update from the other forum by the owner. I did suggest that he utilize TDR and its knowledgable members.


Unfortunately I have few to no options at this point so I must trust the shops ethics. This shop is the only one in the area that would take it at the time of the tow and much of the labor for troubleshooting and tear down is already done, so I'm already heavily invested in this shop. The shop is also puzzled as to why the engine totally quit (and won't restart). That is one of the reasons they gave me as to why they felt it best to pull the head to see if there was any valve/cylinder damage. They also told me that they could/would not warranty the repair unless they were convinced that no other damage was present in the engine????. I am no expert on engines especially diesels, so I am somewhat at the mercy of the shop. I do know they are in contact with the Cummins shop in Roanoke for advice and parts so I hope that works in my favor. Not being able to research and pick a repair shop is one of the perils of the road so I can only hope I get a fair shake and a quality fix.

 

[Bill Stockard]

My post is a copy of a post on the Northwood Owners Forum. My sig does not apply to this situation. Yes, VA is VanAken, I have used it continuously for many years without problem. I see it as restoring the HP/Torque that was downsized because of the auto trans in '99.

Opps, I misread the post...



I sold my Van Aaken box a neighbor with a '99 3500 C&C 5 speed, It did a good job for him and he really liked the way it "awakened" his farm work truck. I couldnn't tell it helped the performance of my truck very much and I don't know why it made my NV5600 "complain" in 6th gear with a 4. 10 ratio rear axle.



Bill

 

[J D Moore]

This is a copy of the follow-up posted on the Northwood Owners Forum. I do not know the owner nor do I have an opinion, this is just FYI.

Got the bad news from the shop this morning that metal from the turbo did make it into the engine. I went to the shop to see it myself and it was not good. The number one cylinder had only 35 lbs compression (normal is 350 lbs). Numbers two and three had similar readings. There were metal chips visible in all six cylinders and visible damage on several valves. When cranking the engine by hand you could hear an audible squeel coming from number one which indicates metal fragments made it down between the piston and cylinder wall. All in all I think I am in the worst case scenario.

Shop is researching the cost trade off between a rebuild vs a new short/long block. Based on what I have seen I think I am heading into new short/long block territory and that will be quite expensive. The one good thing with the new short/long block option will be a 100,000 mile nationwide warranty vs the repair warranty the shop would give me for a rebuild. But since the shop is in Virginia and I live in Mississippi it will be very difficult and expensive for me to get warranty support from the shop, no matter how good intentioned it was. Hate to put that kind of money in 2005 truck but looks like I will be driving this puppy for awhile now. While they are in there I will also have the injector driver and lift pump replaced as they seem to be some other problem components.

All this is very disheartening but it still won't deter me from traveling and camping. We love the Arctic Fox and traveling so we plan to press on!

 

[MChrist]

"WOW" is all I can say!! Those must've been some tiny pieces to get caught in the airflow enough to make it all the way past the intercooler and grid heater and into all 6 cylinders!
Although, I still have my doubts... just pessimistic. I wonder how many pieces are in the inteercooler. He better get that cleaned out or replaced, too!!

 

[AH64ID]

No way just the turbine blew up.

 

[MChrist]

Sounds more like the motor started to seize, scuffed pistons, and blew chunks into the turbo, blowing it up. Just my thought.

 

[NIsaacs]

Sounds like a camshaft failed, as in broke or stopped turning for whatever reason.



Nick

 

[MChrist]

Squealing from #1 piston doesn't sound like a turbo impeller piece blew off the turbo, navigated it's way through the boost tubes, through the intercooler, back up through the other boost tube, up the horn, through the heater grid, past the intake valves, past the rings(???) and lodge between them. I'm still leaning toward a scuffed piston, but what do I know?
I would be interested in learning what the tear-down looks like if you get that far.

 

[J D Moore]

Most recent post from the unfortunate CTD owner:

Looks like my best option for price and availability will be a Jasper Long Block Engine. Jasper offers a two year Nationwide warranty and is available immediately. Dodge offers a stripped down engine (no turbo) with only a six month warranty. Cummins Atlantic has a 12 week lead time for a 5. 9L. So given my situation I have to go with the Jasper. I can only hope this all works out. I have very few options at this point.